Active self-healing biomaterial system

ABSTRACT

Methods and compositions are provided that load and encapsulate an agent, such as a protein, in a porous self-healing polymer. A delivery system includes a porous self-healing polymer, an ionic affinity trap within the pores of the self-healing polymer, and an agent associated with the ionic affinity trap. Methods of encapsulating an agent in a polymer include providing a porous self-healing polymer comprising an ionic affinity trap within the pores. The polymer is incubated with an agent having an affinity for the ionic affmity trap. At least a portion of the pores in the polymer are then healed. Active encapsulation of macromolecules at low concentrations may be achieved due to affinity of the agent for the ionic affinity trap within the pores.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/590,237 filed Jan. 6, 2015, which is a divisional of U.S. applicationSer. No. 13/512,913 filed May 31, 2012, which is a 371 U.S. NationalStage of International Application No. PCT/US2011/021166, filed Jan. 13,2011, and claims the benefit of U.S. Provisional Application No.61/294,666, filed on Jan. 13, 2010, the disclosures of which are hereinincorporated by reference in their entirety.

GOVERNMENT RIGHTS

This invention was made with U.S. government support under grant numberR21 EB008873 awarded by the National Institutes of Health. The U.S.government has certain rights in the invention.

FIELD

The present technology relates to a delivery system with highencapsulation efficiency for an agent such as a biomolecule.

INTRODUCTION

Injectable biodegradable polymeric particles, such as micro spheres,provide a means to deliver and control the release of molecules such asdrugs, proteins, peptides, and vaccine antigens. Once injected, thebiodegradable polymeric particles can release the molecule over thecourse of hours, days, or even weeks to months, providing a distinctadvantage over daily injections in terms of patient acceptability andcompliance. For example, controlled release of a protein antigen canreduce the number of doses in an immunization schedule and can optimizethe desired immune response via selective targeting of antigen toantigen presenting cells. Several biodegradable polymers have beenexplored for the microencapsulation and delivery of macromolecules.Copolymers of lactic acid and glycolic acid (PLGA) are one type ofbiodegradable polymer used in pharmaceutical products or medical devicesincluding several approved by the U.S. Food and Drug Administration. Forexample, PLGAs are used in commercially available controlled-releasepeptide delivery systems, including the Lupron Depot™ (leuprolideacetate), Sandostatin LAR™ (octreotide acetate), and Zoladex™ implant(goserelin acetate).

Unfortunately, successful controlled release of macromolecules such asproteins can be difficult. Stability of the protein during encapsulationand stability during release in vivo are two concerns. And slowly andcompletely releasing therapeutic proteins in their native state frombiodegradable polymeric particles can pose a significant obstacle in thedevelopment of controlled-release injectable depots. Methods forencapsulating macromolecules in biodegradable polymers can involve harshprocessing conditions, including exposure to organic solvents, excessheat, homogenization including mixing, sonication, and high-speedagitation, and so forth, which alone or in combination can denatureand/or destabilize proteins and other macromolecules. Additionally,drying and micronization of the macromolecule prior to encapsulation mayfurther destabilize the macromolecule.

What is more, hydrophilic macromolecules, including many proteins,cannot readily diffuse through a hydrophobic polymer phase, such asPLGA. The release of encapsulated protein drugs from PLGA requires atsome point the diffusion of the macromolecules through water-filledpores and channels. For example, protein release from PLGA microspherescan exhibit tri-phasic behavior. First, protein on the surface or havingaccess to the surface of microspheres (i.e., in open pores) is releasedrapidly, providing an initial burst release. Second, a time lag commonlyexists as the protein cannot diffuse through the polymer phase. Third. acontinuous release of protein occurs following polymer erosion so thatmore pores and channels are formed allowing protein in previouslyisolated pores to be released. There are few exceptions to the lowpermeability rule (i.e., peptides and proteins cannot diffuse throughPLGA) not commonly known, which occur for example, when lower MW PLGAswith acid end groups take up water. In this case, the polymer may alsosorb peptides of moderate MW deep into the polymer phase itself.

Encapsulation methods employing self-healing polymers have beendeveloped to form biodegradable polymeric particles loaded with variousmacromolecules; e.g., peptides, proteins, DNA, siRNA, etc. U.S. Pat.Appl. Pub. 2008/0131478 to Schwendeman et al. describes methods thatobviate damaging stresses during microencapsulation, which includeforming a porous polymer, ideally with a percolating pore network,incubating an aqueous solution of the macromolecules below the glasstransition temperature (T_(g)) of the polymer so that the macromoleculeis taken up into the pores of the polymer, and raising the temperatureabove the T_(g) so that the polymer pores close irreversiblyencapsulating the macromolecule. Other methods can be used to close thepores besides temperature change. For example, exposure to solvent, suchas alcohol vapor, can be used to facilitate self-healing of the polymer.Using this methodology, loadings of about 10% w/w or more can beachieved.

Passive encapsulation methods rely on equilibration of the proteinbetween the solution outside the polymer and the aqueous pores insidethe polymer. Such methods may not provide high encapsulation efficiency;i.e., mass macromolecule encapsulated/mass of macromolecule charged tothe system. As a result, a significant proportion of the macromoleculeto be loaded remains in solution outside the polymer as the polymerpores close. The macromolecule solution may have to be reused multipletimes in this case to avoid wasting the macromolecule. Furthermore,passive encapsulation typically requires very high concentrations of themacromolecule (e.g., >100 mg/mL) in order to achieve elevated loading.Some macromolecules may have limited solubility, prohibiting this methodaltogether.

Accordingly, a need exists for new methods of encapsulatingmacromolecules in pore-containing polymers, such as PLGA, that canincrease the loading and encapsulation efficiency. It is desirable thatthe method could operated without the need for organic solvent or otherharsh processing conditions during encapsulation, which can denatureproteins, for example, and destabilize macromolecules. It is alsodesirable that there would be no need for micronization of themacromolecule, such as protein or nucleic acid, before encapsulation andis desirable that there would be no need for drying, each of which candestabilize macromolecules. The encapsulation method should be lessexpensive to carry out than conventional methods, where cost may be aprincipal factor in the slow development of controlled releaseinjectable depots. For example, passive loading of polymer particles maywaste a considerable amount of macromolecule, leaving a majority of themacromolecule in the solution following pore closure.

SUMMARY

The present technology includes systems, methods, articles, andcompositions that relate to sorbing and/or encapsulating an agent, suchas a biomolecule, with a solid polymer, such as a porous self-healingpolymer, where the polymer may be in the form of particles ormicrospheres. The delivery system may also take on various forms, may bea portion of other forms, or may be coated onto other forms, includingvarious shapes or devices such as drug eluting stents, sutures, screws,tissue engineering scaffolds, and blood circulating nanoparticles, amongothers.

In some embodiments, a delivery system comprises a solid polymer matrixcomprising an ionic affinity trap, the ionic affinity trap is operableto sorb an agent from an aqueous solution. An agent can be sorbed to theionic affinity trap. The solid polymer matrix can be a self-healingpolymer. The self-healing polymer can comprise one or more pores thatcomprise the ionic affinity trap, where at least a portion of the porescan be interconnected. The delivery system can further include an agentsorbed to the ionic affmity trap and wherein the pore partially or fullyencapsulates the agent and prevents the agent from exiting the pore. Thesolid polymer matrix can comprises a biodegradable polymer and cancomprise a copolymer of lactic acid and glycolic acid. The solid polymermatrix can take the form of a microparticle or micro sphere. The ionicaffinity trap can comprise a metal salt, such as aluminum hydroxide,aluminum phosphate, potassium phosphate, magnesium carbonate, calciumphosphate, or combinations thereof, and can comprise an ionomer gel. Theionic affinity trap can comprise ionized end groups of the polymer,where the ionized end groups can comprise carboxylate groups. The agentcan comprise a biomolecule, drug, or antigen, where the biomolecule cancomprise a protein, peptide, proteoglycan, lipoprotein, or nucleic acid.The agent can also comprise an immunocontraceptive. The solid polymermatrix can further comprise a plasticizer.

In some embodiments, a method of making a delivery system comprisessorbing an agent to an ionic affinity trap, wherein a solid polymermatrix comprises the ionic affmity trap and an aqueous solutioncomprises the agent. The method can further comprise partially or fullyencapsulating an agent in a pore by increasing the temperature of theself-healing polymer to about its T_(g) or above, where the solidpolymer matrix includes a self-healing polymer comprising the pore. Theaqueous solution in the sorbing step can comprise less than about 1mg/mL of the agent. At least 90% of the agent in the sorbing step can besorbed to the ionic affinity trap

In some embodiments, a delivery system can include a self-healingpolymer comprising one or more pores, where the pore or pores include anionic affinity trap and an agent, such as a biomolecule, associated withthe ionic affinity trap. The delivery system can be made by providingthe self-healing polymer having one or more pores, where the pore(s)includes an ionic affinity trap. The self-healing polymer is contactedwith an agent having affinity for the ionic affinity trap so that theagent associates with the ionic affmity trap. The self-healing polymercan then partially or fully encapsulate the agent, preventing the agentfrom exiting the pore(s). The delivery system can also include aself-healing polymer where a portion of the self-healing polymercomprises ionized end groups and an agent sorbed to the ionized endgroups. Such a delivery system can be made by contacting theself-healing polymer with an agent having affinity for the ionized endgroups and optionally.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1. Self-healing microencapsulation of large molecules in PLGAmicrosphere injectable controlled-release depots. Scanning electronmicrographs of self-microencapsulating microspheres (SM-1, Tables 1 and2) before (A) and after (B) healing of polymer pores in the presence of230 mg/mL lysozyme at 42.5° C. Laser confocal fluorescent micrographs(C) of the cross-sectional distribution of BSA-Coumarin (in whitedomains) after self-healing encapsulation of the protein in microspheres(20-63 μm in diameter) (SM-2, Tables 1 and 2). Increasing proteinloading by increasing protein concentration exposed to SM-micro spheres(D) (SM-2, Tables 1 and 2) or SM-microsphere porosity (E) with anincreasing volume (25, 100, 200, and 350 μL, open circles) of innerwater phase in the double emulsion or amount (0, 1.5, 4.3, and 11 w/wMgCO₃, closed circles) of porosigen (SM-3, Tables 1 and 2). Kinetics ofself-encapsulation of large molecule in PLGA microspheres (SM-3, Tables1 and 2) after initiating self-healing with increase of T>T_(g) (F). SMmicrospheres were first incubated at 4° C. for 20 h and then at 42.5° C.(time=0 h) with 65 mg/mL dextran-FITC. Values represent mean±SEM, n=3(F) or 5 (D and E) measurements.

FIG. 2. Assessment of lysozyme aggregation and leuprolide controlledrelease after self-healing microencapsulation (SM) without organicsolvent. Insoluble aggregation recorded after microencapsulation ofencapsulation-labile lysozyme (A) according to self-healing(Formulations A-D without organic solvent) and standardsolvent-evaporation (Formulations E and F with organic solvent)processes. SM microspheres were prepared from 11 (Formulations A, and B)and 51 (Formulations C-F) kDa M, PLGA 50/50, and in the presence (B, D,F) and absence (A, C, E) of 0.45 M sucrose in the aqueous lysozymesolution. A: Formulations A and B, C and D, and E and F, respectively,correspond to SM-4, SM-3, and TM-1 in Tables 1 and 2. In vitro and invivo evaluation of controlled-release leuprolide from SM-microspheres(SM-5, Tables 1 and 2). Slow release of leuprolide was observed in aphysiological buffer in vitro (B) and as indicated by serum testosteronesuppression in rats (C). Animals were injected subcutaneously once with1-month dose of soluble leuprolide (filled squares), once with 2-monthdose of leuprolide acetate in SM-microspheres (open diamonds), twice(day 0 and day 28) with commercial 1-month Lupron Depot™ (open squares)or once with blank SM-microspheres containing no drug (open triangles).Dose was based on 100 μg/kg/day. Solid and dashed line respectivelyrepresents lower testosterone detection limit (0.1 ng/mL) and castrationlevel (0.5 ng/mL), respectively. Values represent mean±SEM, n=5measurements (A and B) or 6 animals (C).

FIG. 3. Active self-microencapsulation of ovalbumin (OVA) and tetanustoxoid (TT) in Al(OH)₃ adjuvant-containing SM-microspheres (ASM, Tables1 and 2). Scanning electron micrographs (A, B) depict the SM-microspheremorphology after loading entire OVA mass from 0.5 mg/mL OVA solution andself-healing at 37° C. PLGA plasticized with 0% (A) and 5% (B) diethylphthalate (DEP). A and B formulations respectively correspond to ASM-1and ASM-3 in Tables 1-4. Controlled release of OVA monomer (C) orantigenic TT (D) from active self-microencapsulating microspheresrelative to OVA or TT-loaded aluminum adjuvant without polymer (closedsquares, Al(OH)₁ no PLGA; closed circles, 3.2% Al(OH)₃/3.5%trehalose/PLGA no plasticizer (ASM-1, tables S1-S5); open circles, 3.2%Al(OH)₃/3.5% trehalose/PLGA/5% DEP). Closed and open circlesrespectively represent formulation ASM-1 and ASM-3 in Tables 1-5. Valuesrepresent mean±SEM, n=3 measurements.

FIG. 4. Goodness of self-encapsulation in PLGA microspheres as indicatedby elevated lysozyme loading (open bar chart) and minimal initial burst(closed bar chart) of enzyme employing diversity of pore-formingexcipients/initial water phase volume to create the PLGA 50/50 porenetwork. Formulations A, B, C, and D were respectively prepared with 0,1.5, 4.3, and 11% w/w MgCO₃ and E, F, and G were respectively preparedwith 25, 100, and 350 μL, initial water phase (SM-3, Tables 1 and 2).Values represent mean±SEM, n=3 measurements.

FIG. 5. Self-healing microencapsulation of leuprolide acetate in PLGA50:50 (M_(w)=51 kDa) microspheres (SM-5, Tables 1 and 2). Scanningelectron microscopy image of SM PLGA microspheres before (A) and after(B) self-healing microencapsulation of leuprolide acetate. Actual amountof leuprolide acetate self-encapsulated by this formulation was 3.0±0.2%(w/w peptide/polymer matrix) (5 measurements).

FIG. 6. Protection of protein (BSA and lysozyme) against acid-inducedinstability during release from self-microencapsulated PLGA 50:50(M_(w), =51 kDa) microspheres (SM-3, Tables 1 and 2). (A) Effect ofMgCO₃ (porosigen/stabilizer) loading (3 (⋅) and 4.5 (Δ) % w/w) andaddition of sucrose (0 (▪) and 0.45 (◯) M) in protein loading solutionon cumulative release of BSA from self-microencapsulated microspheres.Actual BSA loading in ⋅, Δ, ▪, and ◯ SM formulations was 4.25±0.05,5.65±0.06, 7.26±0.09, and 5.54±0.04%, respectively. Initial water phase(200 μL) was PBS (pH 7.4) with (▪ and ◯) or without trehalose (500 mg in1 g PBS). (B) Effect of MgCO₃ (porosigen/stabilizer) loading (0 (⋅), 1.5(Δ), 4.5 (♦), and 11 (

) % w/w) on cumulative release of lysozyme from self-microencapsulatedmicrospheres. Actual lysozyme loading in ⋅, Δ, ♦, and

SM formulations was 4.2±0.2, 6.4±0.1, 9.8±0.3, and 8.7±0.4%,respectively. In vitro release studies were conducted in PBST at 37° C.and symbols represent mean±SEM (three measurements).

FIG. 7. Effect of encapsulation of Al(OH)₃ and blending of hydrophobicplasticizer (diethyl phthalate (DEP)) on the self-healing phenomenon ofPLGA 50:50 (M_(w), =51 kDa) microspheres. Surface morphology of blank(3.5% w/w trehalose loaded), ASM-1, ASM-2, and ASM-3 PLGA microspheresbefore and after self-healing microencapsulation process. ASM-1, ASM-2,and ASM-3 PLGA microsphere formulations consists of 3.2% w/w Al(OH)₃ and3.5% w/w trehalose as porosigen and Al(OH)₃ lyophilization stabilizer.ASM-2 and ASM-3 contain 2.5 and 5% w/w DEP, respectively. Blank andASM-1 PLGA microspheres were incubated at 25 and 43° C. for 48 h. ASM-2and ASM-3 PLGA microspheres were incubated for 48, 24, and 30 h at 10,25, and 37° C., respectively. Preparation process of blank ASM PLGAmicrospheres is given in Table 1.

FIG. 8. Evaluation of quality of active protein self-microencapsulationin Al(OH)₃—PLGA 50:50 (M_(w), =51 kDa) (ASM PLGA) microspheres in 190 mMsodium citrate solution. Cumulative ovalbumin released as a function oftime from unencapsulated Al(OH)₃ gel (control) (▪) and with (◯) (ASM-3,Tables 3 and 4) and without (●) (ASM-1, Tables 3 and 4) 5% w/w DEP inAl(OH)₃—PLGA microsphere formulations. In vitro release studies wereconducted at 37° C. and symbols represent mean±SEM (three measurements).

FIG. 9. Photomicrographs of 3.2 wt % alhydrogel/3.8 wt % trehalose/PLGAmicroparticles before (A) and after (B) self-healing at 25° C. for 24 hand 43° C. for 48 h.

FIG. 10. Photomicrographs of 3.2 wt % alhydrogel/3.8 wt % trehalose/2.5wt % DEP/PLGA microparticles before (A) and after (B) self-healing at10° C. for 48 h, 25° C. for 24 h, and 37° C. for 30 h.

FIG. 11. Photomicrographs of 3.2 wt % Alhydrogel/3.8 wt % Trehalose/5 wt% DEP/PLGA microparticles before (A) and after (B) self-healing.

FIG. 12. Evaluation of in vitro release of leuprolide acetate (LA) fromLA-PLGA particles. Cumulative amount of LA released as a function ofincubation time in PBST at 37° C. The actual loading of LA in LA-PLGAparticles was about 17 wt %. Symbols represent mean±SE, n=3.

FIG. 13. Prolonged serum testosterone suppression by leuprolide acetate(LA)-PLGA particles in male Sprague-Dawley rats. Effect of dosinginterval (2X, 3X, and 4X) of LA-PLGA particles on serum testosteronesuppression. Animals were injected subcutaneously with 1× (day 0)soluble leuprolide (●), LA-PLGA particles with different dosing interval(2X: day 0, 14, 28, and 42 (▴), 3×: day 21 and 42 (⋄), and 4×: day 0 and28 (▾)), and blank PLGA particles (◯) in a liquid vehicle (1% w/vcarboxymethylcellulose and 2% w/v mannitol) along with 2× (day 0 and 28)commercial 1-month Lupron Depot (

). The dose of leuprolide acetate was 100 μg/kg/day. Solid and dashedline respectively represents lower testosterone detection limit andcastration level. Symbols represent mean±SEM, n=6. Lowest detectionlimit of testosterone was 0.1 ng/m L.

DETAILED DESCRIPTION

The following description of technology is merely exemplary in nature ofthe subject matter, manufacture and use of one or more inventions, andis not intended to limit the scope, application, or uses of any specificinvention claimed in this application or in such other applications asmay be filed claiming priority to this application, or patents issuingtherefrom. A non-limiting discussion of terms and phrases intended toaid understanding of the present technology is provided at the end ofthis Detailed Description.

Preparation of controlled-release polymeric biomaterials generallyrequires an organic solvent during drug microencapsulation, limitingboth biomaterial design and applications for large molecular drugs. Thepresent technology provides a new microencapsulation paradigm based onspontaneous self-healing of polymers. For example, biomolecules such aspeptides, proteins, or polysaccharides dissolved in aqueous solution canbe self-microencapsulated in poly(lactic-co-glycolic acid) (PLGA) byplacing the biomacromolecule solution in contact with solid PLGA,preformed with an interconnected pore-network, at below the polymerglass transition temperature (T_(g)), and then healing the pores at atemperature at or above the T_(g). Healed polymers can then slowlyrelease the biomacromolecules under physiological conditions for over 1month. Benefits of the present approach include improved compatibilitywith biotechnology-derived drugs, reduced manufacturing cost andresidual organic solvent, the ability to create new biomaterialarchitectures, and facile use among non-formulation scientists andclinicians.

Modern synthetic polymeric biomaterials are widely used to slowlyrelease medicines over days to years after administration to the body.These polymers are configured in numerous biomedical and pharmaceuticalthree-dimensional forms (e.g., spheres, rods, coatings, porous matrices)including micro- to millimeter scale injectable depots, drug-elutingstents, scaffolds for engineering tissues, and blood-circulatingnanometer scale particles and can be made biodegradable ornondegradable. Until now, drugs, particularly peptides and proteins, aremost commonly microencapsulated by first combining drug with a polymerdissolved in organic solvent. Before or after this combination the drugis either micronized (e.g., by homogenization, sonication, or grinding)or molecularly dissolved in the solvent, to yield drug domains, whichlater become dispersed in the final polymer matrix. Both steps cancompromise stability of encapsulated proteins and other biomolecules.The organic solvent is removed to clinically acceptable levels and thepolymer is dried before use. Described here is a newself-microencapsulation paradigm based on the polymer's own spontaneous“self-healing” capacity in aqueous media. Features of this new approachinclude a simple mixing process (e.g., as mixing naked DNA to lipofectingene delivery vector), the absence of exposure of drug to organicsolvent during encapsulation (e.g., as supercritical fluid polymerprocessing), and mild processing conditions (e.g., as spray-congealingfor commercial manufacture of PLGA-encapsulated growth hormone).

To illustrate this new paradigm, injectable self-microencapsulating (SM)microsphere (SM-1, Table 1) depots of biocompatible copolymers of lacticand glycolic acids (PLGA) were prepared by a standard emulsion-basedmethod with leachable trehalose to create interconnected porous networkin the polymer, but without including an agent such as a biomolecule ordrug. After leaching the sugar, pores on the scale of 250 to 2500 nmwere easily viewed by electron microscopy (FIG. 1A). The drymicrospheres were incubated at 4° C. (<<hydrated T_(g)˜30° C.) inconcentrated aqueous lysozyme solution at 230 mg/mL for 48 h to allowthe protein to enter the open polymer pores. Self-healing of the poreswas initiated without organic solvent by raising the temperature toabout or greater than the T_(g) to 42.5° C. for 44 h (SM-1, Table 2),resulting in lysozyme-encapsulated microspheres with 3.8±0.1% proteinloading (w/w protein/polymer matrix, 5 measurements) and a nonporouspolymer surface (FIG. 1B).

Large molecules penetrate deep within the polymer matrix prepared bythis method, as viewed by laser scanning confocal micrographs of healedSM microspheres prepared with fluorescent coumarin-labelled BSA (FIG.10). Moreover, molecules as large as 2 million Da were found to enterthe polymer pore network and become self-encapsulated, as indicated bythe similar loading in the polymer of 2 MDa and 4 kDafluorescent-labeled dextrans. Protein loading determined after extensivewashing of SM microspheres was found easily adjustable, for example, asseen by the sensitivity of BSA (FIG. 1D) and lysozyme (FIG. 1E) loading,respectively, to initial protein loading solution concentration (SM-2,Tables 1 and 2) and dry SM polymer porosity (SM-3, Tables 1 and 2). Totest the goodness of encapsulation, SM microspheres prepared by severaldifferent conditions were loaded with protein and incubated underphysiological conditions (in PBS+0.02% Tween 80, pH 7.4 at 37° C.) for48 h to observe the “initial burst release” of protein (FIG. 4), whichis often too high with poorly encapsulated material. SM microsphereswith elevated protein loading of 1.2±0.1 to 9.8±0.3% (5 measurements)and optimal porosigen loading (e.g., 1.5-4.5% (w/w magnesiumcarbonate/polymer matrix), 5 measurements) typically exhibited anoptimal initial burst release of protein (<20% release). Importantly,the measured loading and initial burst values were within the desirablerange as established by clinically used PLGA depots and required loadingtimes were on the order of 12 hours (FIG. 1F).

As expected by the mild encapsulation conditions (37-43° C. temperatureexposure) by the new approach—no harsh mixing or organic solventexposure—protein stability was also improved with SM microspheresrelative to microspheres prepared by traditional emulsion-basedmicroencapsulation techniques (e.g., water-in-oil-in-water—solventevaporation, w/o/w, as used for the Lupron Depot). For example, usingthe model enzyme, lysozyme, well-established to undergo aggregationduring solvent evaporation, the potential stability improvement of theenzyme in SM microspheres was evaluated relative to solvent evaporationcontrol groups. In formulations with two different MW polymers with andwithout addition of protein-stabilizing sucrose, the stability oflysozyme was improved with SM microspheres in each case (FIG. 2A), andwhen loading by self-healing in the presence of sucrose, negligibleaggregation or activity losses of the enzyme were detected.

Desirable polypeptides were also successfully self-microencapsulated byPLGAs and released slowly and continuously over a period of >1 month.For example, the most commonly delivered peptide from PLGA depots,leuprolide acetate, used to suppress testosterone in prostate cancerpatients to inhibit growth of the hormone-dependent cancer, was loadedin SM PLGA microspheres employing an ionic affinity trap, ZnCO₃, tocreate pores for self-encapsulation and to facilitate continuous releaseof peptide. The resulting SM microspheres (FIG. 5) encapsulated 3.0±0.2%(w/w peptide/polymer matrix) leuprolide acetate (5 measurements) andreleased the peptide in vitro slowly and continuously for 2 months (FIG.2B). After administration of a single injection of the same formulationin rats, slow release of leuprolide acetate was observed, as indicatedby the steady suppression of testosterone (FIG. 2C) (owing todown-regulation of LHRH receptors) before escaping castration levelsafter 6-weeks. Similar behavior was observed after two injections of the1-month Lupron Depot™ formulation, whereas both negative control groups,leuprolide acetate-free SM-microspheres and a 1-month dose of solutionleuprolide, were ineffective to suppress testosterone. Model proteins,bovine serum albumin and lysozyme, were also slowly released, albeit ina first-order fashion (FIG. 6), without any signs of classicacid-induced aggregation of BSA and with full monomeric and enzymaticactivity recovery of lysozyme in the polymer after 1-month releaseincubation. Note that in this example, the leuprolide does not freelydiffuse across the polymer phase (which does not have acidic endgroups), and thus the peptide likely distributes to the polymer poresduring encapsulation.

Ultimate success of microencapsulation of expensive biotech drugsrequires minimal drug losses during encapsulation. In a single batchprocess with SM micro spheres, the percentage of drug from the loadingsolution retained within the final particles, i.e., the encapsulationefficiency (EE), is low (˜1.5-13%) by the passive process. However, aswith minimal or no peptide or protein damage occurs uponself-microencapsulation, the loading solution could be reasonablyrecycled multiple times with concentration adjustment. A similar issuewas resolved in the marketed Doxi1™ stealth liposomes by the activeloading of doxorubicin via precipitating the drug with ammonium sulfateas it diffused into the empty liposome.

We investigated active loading strategies using two vaccine antigens(ovalbumin (OVA) and tetanus toxoid (TT)). For example, OVA or TTprotein antigens were loaded into SM PLGA containing, as an ionicaffinity trap, lyophilization-stabilized Al(OH)₃ adjuvant (ASM, Table1), which absorbed the antigen into the polymer matrix from surrounding0.5 or 0.8 or 1 mg/mL antigen solution, with 98±1% EE (6 measurements)and 1.0±0.05% OVA loading (6 measurements) (ASM-3, tables S3 and S4) or87±0.4% EE (3 measurements) and 1.6±0.03% TT loading (Table 5). Extentof self-healing of polymer pores was also easily enhanced at 37° C. inthe active-loading microspheres by addition of a plasticizer, diethylphthalate (DEP), to the polymer to further mobilize the hydrated polymerchains (FIG. 7). After self-microencapsulation, decreased surfaces poresare visible with plasticizer added (FIGS. 3A and B). Vaccine antigenswere effectively self-encapsulated with the active loading strategy inboth preparations, as indicated by slow-release of the antigens relativeto unencapsulated A1(OH)₃ in 190 mM sodium citrate (FIG. 8), phosphatebuffered saline (PBS) (FIG. 3C), and PBS+0.02% Tween® 80+0.2% BSA (FIG.3D). Hence, it is now possible to self-microencapsulate in biodegradablepolymers the entire mass of bioactive macromolecules from a lowconcentration aqueous solution by simple mixing and heating of thesolution with an SM-polymer matrix. Also noteworthy were a) the absentrequirement of a drying step after microencapsulation of OVA and TT, asdrying can cause irreversible damage to proteins, and b) the completerelease of antigenically active TT without any apparent commonformaldehyde or acid-induced antigen instability.

Spontaneous self-healing in homogenous polymer systems has beendescribed in nano-scale cracks of solid rocket propellants, followingbullet holes in plastic plates, film formation from latex particles, andacross lap joints of polymer films. The process mechanism, which hasfound to be ubiquitous to polymers in the vicinity of their T_(g) orabove has been analyzed in detail to involve multiple elements such as:a) polymer chain interdiffusion, b) minimization of energeticallyunfavorable interfacial area, and c) transfer of energy stored in adefect. We first observed spontaneous pore closing in PLGA microspheresthat encapsulated a water-soluble polypeptide during the initial burstrelease of peptide less than 24 hours after exposure of the polymer toaqueous media at physiological temperature; the resulting closure of thepeptide release route initiated a lag phase in release characteristic ofthis polymer when above a critical MW. Initial studies thereafter todemonstrate the self-encapsulation paradigm in aqueous media attemptedto obtain high loading with low initial burst (as seen in FIG. 1F)suffered from poor interconnected networks or pore networks which wouldnot close (likely due to very high porosity of the polymer). We foundthat polymer matrices with moderate porosity and defects ˜2 μm of less(FIG. 1B) could be healed in aqueous solution when pores were created bysugar or salt similarly as those observed during the initial peptiderelease. Consistent with previous mechanistic analysis,self-encapsulation requires a minimum temperature for polymer-chainmobility to occur over reasonable time scales (FIG. 1F).

The benefits and uses of the self-microencapsulating paradigm are farreaching. For example, a clinician can mix sterile SM microspheres withan injectable solution of vaccine (e.g., tetanus toxoid) beforeinjecting into women of child-bearing age, providing improved immunityfor their unborn children against neonatal infection. New biomaterialarchitectures (e.g., drug-eluting stent coatings) that releaseprocess-sensitive large molecules as previously unchartered formulationconditions (e.g., high temperature, reactive molecules, organic solvent)can be used to create the SM polymer delivery system without concern ofdamaging the encapsulated macromolecule. For manufacturing, a mixture ofseveral different SM microsphere formulations, each having distinctdesign characteristics (release kinetics, size, surface biofunctionalgroups) can be combined for a drug of interest in a single sterilemixing step. With the absence of aseptic processing of organic solvents,this paradigm can have significant cost savings, which was a criticalfactor in halting production of the Nutropin Depot, the first and onlyFDA approved injectable protein depot. The simplicity ofself-microencapsulation can also significantly facilitate variouscontrolled release approaches, providing more rapid advancement ofcontrolled release products and technology.

The following materials and methods were employed to demonstrate thepresent technology.

Materials: Poly(D,L-lactic-co-glycolic acid) (PLGA) 50:50 with ani.v.=0.20 dl/g in hexaflouro isopropanol at 30° C. (Lot # A07-044,end-group=1-dodecyl ester, weight average molecular weight (M_(w))=11kDa) of Lactel Absorbable Polymers was purchased from DURECT Corporation(Cupertino, Calif., USA). PLGA 50:50 with an i.v.=0.19 dl/g inchloroform at 30° C. (Lot #1158-515, end-group=methyl ester, M_(w)=19kDa) and 0.57 dl/g in hexafluoroisopropanol at 30° C. (Lot # W3066-603,end-group=lauryl ester, M_(w)=51 kDa) were purchased from LakeshoreBiomaterials (Birmingham, Ala., USA). α,α-Trehalose dihydrate waspurchased from Pfanstiehl (Waukegon, Ill., USA), zinc carbonate (ZnCO₃)was from ICN Biomedicals Inc., and 7-methoxycoumarin-3-carbonyl azidewas from Invitrogen Corporation (Carlsbad, Calif., USA). Tetrahydrofuron(THF) was purchased from Fisher-Scientific (Pittsburgh, Pa., USA).Tetramethyl-rhodamine (TMR)-dextran was purchased from InvitrogenCorporation (Carlsbad, Calif., USA). Tetanus toxoid (TT) (3120 Lf/mL)and equine tetanus antitoxin were received as gift samples respectivelyfrom Serum Institute of India Ltd. (Pune, India) and U.S. Food and DrugAdministration (Silver Spring, USA). Human tetanus immune globulin(HyperTET™ S/D, 250 units) was purchased from Talecris Biotherapeutics,Inc. (Research Triangle Park, N.C., USA). Poly(vinyl alcohol) (PVA)(9-10 kDa, 80% mol hydrolyzed), Alhydrogel™ aluminum hydroxide adjuvantgel (Al(OH)₃), bovine serum albumin (BSA) fraction V, ovalbumin (OVA),lysozyme from chicken egg white, sodium hydroxide (NaOH), magnesiumcarbonate (MgCO₃), BSA labeled with fluorescein isothiocyanate(BSA-FITC), sodium citrate, p-nitrophenyl phosphate liquid substrate,and phthaldialdehyde reagent (containing 1 mg o-phthaldialdehyde per mLsolution of 2-mercaptoethanol as the sulfhydryl moiety) were purchasedfrom Sigma-Aldrich (St. Louis, Mo., USA). Leuprolide acetate (Batch#091203) was purchased from Shanghai Shjnj Modern PharmaceuticalTechnology Co., Ltd (Shanghai, China). Male Sprague-Dawley rats wereprocured from Charles River Laboratories. Isoflurane was purchased fromBaxter Healthcare Corporation (Deerfield, Ill., USA). B-D Microtainer™blood collection and serum separation tubes were purchased from Becton,Dickinson and Company (Franklin Lakes, N.J., USA). Goat anti-humanIgG-alkaline phosphatase was purchased from Jackson ImmunoResearchLaboratories, Inc. (West Grove, Pa., USA). All other common salts,reagents, and solvents were purchased from Sigma-Aldrich. Sizeexclusion-high performance liquid chromatography (SE-HPLC) columns (TSKgel G3000SWx1 and TSK gel G2000SWx1 columns, Tosoh Biosciences LLC,Montgomeryville, Pa., USA), Shodex Protein KW-G size exclusionchromatography guard column (Showa Denko, N.Y., USA), Nova-Pak C18column (4 μm, 3.9×150 mm) and Bonda-Pak C18 guard column (4 μm) (WatersCorporation, Milford, Mass., USA) were used.

Conjugating BSA to a pH-insensitive fluorescent coumarin: About 1.2 gBSA was dissolved in 40 mL of 0.2 M sodium bicarbonate (pH 4.5). Tothis, 2 mL of 10 mg/mL 7-methoxycoumarin-3-carbonyl azide in dimethylsulfoxide (DMSO) was added while stirring. The solution was stirredcontinuously at room temperature in darkness for 90 min. To quench thereaction, 4 mL of 1.5 M hydroxylamine hydrochloride was added and thenthe solution was extensively dialyzed using a 25,000 Da M_(w) cut-offmembrane against degassed distilled water at 4° C.

Preparation of self-microencapsulating (SM) PLGA microspheres: Variousformulations of self-microencapsulating PLGA 50:50 (M_(w)=11, 51, and 19kDa) microspheres (Table 1) were prepared by a double emulsion(water-in-oil-in-water (W/O/W))-solvent evaporation method without drug.Briefly, polymer solutions of various PLGAs were first prepared bydissolving the required amount of polymer in 1 mL methylene chloride(CH₂Cl₂) in a 5- or 10-mL syringe or 10-mL glass tube. Suitable initialwater phase (WP) was added to the corresponding polymer solution andimmediately homogenized as per the first homogenization conditionsspecified in Table 1 using a Tempest IQ² homogenizer (The VirTisCompany, Gardiner, N.Y., USA) equipped with a 10 mm shaft in an icewater bath to create the respective first emulsion. Two mL of aqueous 5%PVA was added to the first emulsion of all the formulations, vortexed orhomogenized as per the second homogenization/vortexing conditions (Table1), and the resulting emulsion was injected into 100 mL of chilled (ASMmicrospheres) or non-chilled (TM-1 and SM-1 to SM-5 microspheres) 0.5%PVA solution under continuous stirring. Microspheres were stirred 3 h atroom temperature, and collected with sieves to separate by size (20-63and 63-90 μm) and washed thoroughly with distilled water to help removeresidual PVA. Collected SM PLGA microspheres were then freeze-driedusing a freeze drier (Labconco Corporation, Kansas City, Mo., USA) andstored at −20° C. until further use.

TABLE 1 Formulation conditions for preparing traditional (lysozymeencapsulated) and various types of SM PLGA 50:50 microspheres. PLGA50:50 Conc. (mg polymer in 1 WP Formulation Initial water phase M_(w) mLCH₂Cl₂) + volume First Second homog./ code (WP) composition (kDa)excipient (μL) homog. vortexing SM-1 500 mg trehalose in 51 320 17520,000 rpm Homog. at 6000 1 g PBS for 1.5 min rpm for 45 s SM-2 300mg/mL BSA in 19 700 150 10,000 rpm Vortexing for 15 s PBS for 1 min SM-30 or 500 mg 51 320 + 0, 4.8, 25, 100, 17,000 1 rpm Homog. at 6000trehalose in 14.4, and 39.5 200, and for 1 min rpm for 25 s 1 g PBS mgMgCO₃ 350 SM-4 500 mg trehalose in 11 1100  175 20,000 rpm Homog. at6000 1 g PBS for 1.5 min rpm for 45 s TM-1 200 mg/mL 51 320 110 20,000rpm Homog. at 6000 lysozyme with or for 1.5 min rpm for 45 s without0.45M sucrose in water SM-5 1 g PBS or 500 mg 51 320 + 0, 3.5, 20010,000 rpm Vortexing for 15 s trehalose in and 10 mg for 1 min 1 g PBSZnCO₃ ASM 300 μL of 25 mM 51 250 + 0, 7, 200 17,000 rpm Vortexing for 50s succinate buffer (pH and 14.2 mg for 1 min 4.0) containing 13.1- DEP13.8 mg Al(OH)₃ gel and 14.1-15 mg trehalose SM: self-microencapsulatingPLGA microsphere formulation; TM: traditional PLGA microsphereformulation; ASM: active self-microencapsulating PLGA microsphereformulation; CH₂Cl₂: methylene chloride; M_(w): molecular weight; PBS:phosphate buffered saline (pH 7.4); MgCO₃: magnesium carbonate; ZnCO₃:zinc carbonate; DEP: diethyl phthalate; Conc.: concentration

TABLE 2 Conditions for investigating passive and activeself-microencapsulation of enzyme/protein/peptide by various types ofPLGA 50:50 SM microspheres. SM Concentration Enzyme/protein/microspheres of loading Incubation temperature/duration peptide self-added solution:volume (° C./h) FC encapsulated (mg) (mg/mL:mL) LoadingSelf-healing SM-1 Lysozyme 200 or 225 200 or 230:1 or 1.4 4/48 42.5/44  SM-2 BSA-coumarin 125 43 or 79 or 115 or 4/24 or 48 37 or 42/18 or 157or 175 or 204:0.8 24 or 1 SM-3 BSA or Lysozyme 50 or 100 1 (TMR-Dextranor 4/24 or 48 (TMR- 42.5/48 or 72 or TMR-Dextran (FITC-Dextran/FITC-Dextran) or 65 Dextran or FITC- (TMR-Dextran or FITC-DextranTMR-Dextran) (FITC-Dextran) or Dextran) or 4/16 or FITC- 80 or 150 (BSA/200 or 300 (BSA or or 72 (BSA or Dextran) or Lysozyme) Lysozyme with orLysozyme) 43/46 or 48 without 0.45M (BSA or sucrose):1 Lysozyme) SM-4Lysozyme 200 250 with or without 4/24 37/12 0.45M sucrose:1 SM-5Leuprolide acetate 1000  127:4 4/42 43/48 ASM OVA or TT  20 0.5 or1.0:0.4 (OVA) 10/48 (OVA) or 37/30 (OVA) or or 0.8:0.5 (TT) 24 (TT) +25/24 38/40 (TT) (OVA and TT) FC: formulation code; SM:self-microencapsulating PLGA microsphere formulation; ASM: activeself-microencapsulating PLGA microsphere formulation; OVA: ovalbumin;TT: tetanus toxoid.

Passive and active self-healing microencapsulation of large molecules(lysozyme, BSA, leuprolide, OVA and TT) by PLGA Microspheres: Thepassive self-microencapsulation paradigm was studied using all themicrospheres formulations given in Table 1, except Al(OH)₃-encapsulatedPLGA microspheres, which were used for testing activeself-microencapsulation of OVA and TT. Briefly, microspheres of 20-63 μmsize were incubated with chilled (4° C.) enzyme/protein/peptide solutionon a rocking platform (VWR Scientific, West Chester, Pa., USA) at 4° C.(loading conditions) for a specified period of time, as listed in Table2. After completion of loading duration, microspheres were thentransferred on a rigged rotator (Glas-Col, Terre Haute, Ind., USA) toprevent interparticle healing in an incubator maintained at specifiedtemperature for specified duration (self-healing conditions), as listedin Table 2. Microspheres were then removed, washed 10 times withdistilled and deionized water (ddH₂O), centrifuged at 3000-3800 rpm for5-10 min, and freeze-dried. To test active self-microencapsulation,about 21 mg Al(OH)₃-encapsulated PLGA microspheres of 20-63 μm size wereincubated with low protein (OVA or TT) concentration solution (0.5-1.0mg/mL, volume=0.4 or 0.5 mL) on a rigged rotator for a specifiedduration at 10 and 25° C. for active protein loading and then at 37 or38° C. for self-healing (Table 2). Microspheres were then removed,washed one time with ddH₂O, centrifuged with conditions given above andsupernatant was removed. Microspheres were used without drying.

Preparation of lysozyme encapsulated PLGA microspheres by a traditionalencapsulation (TE) method: As summarized in Table 1, one hundred ten μLof 200 mg/mL aqueous lysozyme solution with or without 0.45 M sucrosewas added to 320 mg PLGA (50:50, M_(w)=51 kDa) in 1 mL CH₂Cl₂ andimmediately homogenized in a 5-mL-syringe at 20,000 rpm for 1.5 min,creating the first emulsion. Two mL of 5% PVA was immediately added tothe tube and the mixture was then homogenized for 45 s at 6,000 rpm andthe resultant emulsion was injected into 100 mL of 0.5% PVA undercontinuous stirring. Microspheres were stirred for 3 h at roomtemperature, and collected with sieves to separate by size (20-63 and63-90 μm) and washed thoroughly with ddH₂O to help remove residual PVA.

Coomassie (modified Bradford) protein assay: A modified Bradford assaywas used to determine protein concentrations. Briefly, appropriatevolume of standard or sample was mixed with Coomassie Plus™ reagent(Thermo Fisher Scientific, Rockford, Ill., USA) in a 96-well plate(Nalge Nunc International, Rochester, N.Y., USA). Then, the absorbancewas read at 595 nm within 30 min using a Dynex II MRX microplate reader(Dynex Technology Inc., Chantilly, Va., USA).

Size exclusion-high performance liquid chromatography (SE-HPLC) analysisof protein: Samples were injected into the TSK Gel G3000SW (lysozyme,BSA and BSA-Coumarin) or G2000 SW (OVA) column (7.8 mm i.d.×30 cm long)column (Tosoh Biosciences LLC, Montgomeryville, Pa., USA) attached witha Shodex™ Protein KW-G guard column (Showa Denko, N.Y., USA), eluted by0.05 M potassium phosphate containing 0.2 M NaCl (pH 7.0) for (lysozymeand OVA) or PBS (pH 7.4) for (BSA and BSA-Coumarin) at a flow rate of0.9 for (lysozyme, BSA and BSA-Coumarin) or 0.7 (OVA) mL/min. UVdetection at 215 and 280 nm and fluorescence detection with excitationand emission wavelengths of 278 nm and 350 nm for BSA, OVA and lysozyme,and 384 nm and 480 nm for BSA-Coumarin were used.

High performance liquid chromatography (HPLC) analysis of leuprolideacetate: Analysis of leuprolide acetate was accomplished by HPLC, with agradient of acetonitrile (Solvent A) and 0.05 M sodium phosphate buffer,pH 7.0 (Solvent B) on a Nova-Pak C18 column (4 μm, 3.9×150 mm, WatersCorporation, Milford, Mass., USA). The gradient method was 0 min (20%A), 6 min (30% A), 9.5 min (37% A), 11.5 min (37% A), 16.5 min (50% A),and 19 min (20% A), followed by a 2 min recovery. UV detection wasmeasured at 215 nm and 280 nm, and fluorescence detection was performedat excitation and emission wavelengths of 278 and 350 nm, respectively.

Determination of active loading by protein disappearance from theloading solution: To follow active loading (i.e., mass fraction ofencapsulated species in PLGA) as a function of time and temperature ofincubation, after various stages of the incubation, the protein/activeSM (Al(OH)₃-encapsulated) PLGA microsphere mixtures were passed througha low protein binding PVDF membrane filter (Millipore, Bedford, Mass.,USA) and remaining protein (OVA or TT) in solution was analyzed by themodified Bradford assay.

Determination of loading by polymer removal and recovery of residualprotein/peptide: For determination of soluble lysozyme, BSA, andBSA-Coumarin, PLGA microspheres were dissolved in acetone and dispersedfor 1 h, centrifuged at 13,000 rpm for 10 min and the supernatant wasremoved. Centrifugation/supernatant removal was repeated 3-fold, and theresidual solvent was removed via concentrator (Vacufuge™ concentrator5301 (Eppendorf International, Hamburg, Germany)). The remaining proteinwas then dissolved in 10 mM potassium phosphate buffer, pH 7.0(lysozyme) or PBS, pH 7.4 (BSA and BSA-Coumarin) and analyzed bySE-HPLC.

Leuprolide acetate content in self-encapsulated PLGA microspheres wasdetermined by two-phase extraction. Briefly, about 5 mg leuprolideacetate self-encapsulated PLGA microspheres (n=5) were weighed into 5-mLglass vials. To these vials, 1 mL of methylene chloride and 2 mL of 50mM sodium acetate (pH 4.0) were added, followed by vortexing for 1 min.One and a half mL of buffer layer was removed, replaced with 1.5 mL ofsame buffer (2 extractions) or 50 mM sodium acetate +1 M NaCl (3extractions) and extracted. The content of leuprolide acetate in eachextracted fraction was then analyzed and quantified by HPLC. Fiveextractions were found to be sufficient to remove leuprolide completelyfrom PLGA microspheres as the HPLC peak of leuprolide acetatedisappeared by the 6^(th) extraction.

To determine the OVA content in active self-encapsulated PLGAmicrospheres, microspheres were dissolved in ethyl acetate andcentrifuged at 6,000 rpm for 5 min. The supernatant polymer solution wasremoved and the aluminum hydroxide-OVA sediment was washed twice withethyl acetate. The sediment was then dried at 30° C. using the Vacufuge™to remove ethyl acetate. One milliliter of 190 mM sodium citratesolution was added to the dried aluminum hydroxide-OVA pellet, mixedthoroughly, and incubated at 37° C. for 3 days with constant agitation.In control studies, this duration was determined to be sufficient forcomplete elution of OVA from the aluminum hydroxide gel. Then, thesamples were centrifuged at 6,000 rpm for 5 min and soluble OVA amountin supernatant was analyzed by the SE-HPLC. To the remaining residue, areducing and denaturing solution (10 mM dl-dithiothreitol+6 M urea+1 mMEDTA) was added to dissolve any aggregate and centrifuged. The contentof insoluble aggregate of OVA in supernatant was analyzed by themodified Bradford assay (Si).

Enzyme-linked immunosorbent assay (ELISA): Antigenically active TT wasdetermined by the ELISA. Except for final incubation step withp-nitrophenyl phosphate liquid substrate, all initial ELISA steps wereperformed at room temperature. Briefly, 100 μL of 2-3 internationalunits (IU)/mL of equine tetanus antitoxin in PBS (pH 7.2) was added to96-well microtitration plates (Nalge Nunc International, Rochester,N.Y., USA) and incubated overnight. The plates were washed 3-5 timesbetween all steps with PBS containing 0.05% Tween™ 20 (pH 7.2).Phosphate blocking buffer (PBB, PBS/0.5% BSA/0.05% Brij™ 35, pH 7.4) wasused as a diluent for all TT samples and antibodies (except equinetetanus antitoxin above). Standard TT with known concentration and testsamples were diluted at 2-fold steps in coated plates using PBB as adiluent. The plates were held for 2 h and washed. Then, 100 μL of humananti-TT IgG (HyperTET™ S/D, 1:5000 dilution) was added and allowed toreact for 2 h followed by 100 μL of goat anti-human IgG-alkalinephosphatase diluted 1:20000 in PBB for another 2 h. The plates werewashed and 1004 of p-nitrophenyl phosphate liquid substrate was added.After 30 min incubation at 37° C., the absorbance was read at 405 nm ona Dynex II MRX microplate reader (Dynex Technology Inc., Chantilly, Va.,USA) equipped with Revelation 4.21 Software. Log/Logit curve fittingmodel was used to plot the standard curve and calculate unknownconcentration of TT in test samples.

Evaluation of in vitro release of protein and peptide from SM and TEPLGAmicrospheres: In vitro release of large molecules from passive andactive self-encapsulated PLGA microspheres was determined by quantifyingeither the amount released into the release medium (BSA, lysozyme, TT,and OVA) or the amount of encapsulated species directly remaining in thepolymer (leuprolide acetate). Briefly, ˜4-10 (passiveBSA/lysozyme/leuprolide acetate SM PLGA microspheres) or 20 (active OVAor TT self-encapsulated Al(OH)₃—PLGA micro spheres) mg of microsphereswere incubated in either 0.5-1.5 mL of phosphate buffered saline(PBS)+0.02% Tween 80 (PBST) (pH 7.4) or both PBS and 190 mM sodiumcitrate (active OVA self-encapsulated Al(OH)₃—PLGA microspheres) orPBST+0.2% BSA (active TT self-encapsulated Al(OH)₃—PLGA microspheres) at37° C. under constant agitation (100 rpm/min). Release medium wasremoved and replaced with fresh buffer at pre-selected time points.Soluble BSA/OVA/lysozyme in release media was quantified by SE-HPLC andmodified Bradford protein assay. Release of antigenic TT was determinedby ELISA. In order to determine the in vitro release of leuprolideacetate, peptide remaining in the polymer after incubation of specifiedperiod was determined by the method described in the loading analysis.Cumulative amount of peptide released was then calculated by subtractingthe remaining amount of peptide in the polymer from initial peptidecontent (S2).

Determination of soluble and insoluble lysozyme loading by amino acidanalysis (AAA): Determination of total and soluble lysozyme content inmicrospheres and soluble lysozyme content in other solution-basedsamples was performed by AAA. Briefly, microspheres (˜4 mg), solubleprotein solutions, and standard samples were weighed into clear glassampoules in a total volume of 1.5 ml 6 N HCl. Ampoules were then sealedunder light vacuum and incubated at 110° C. for 25 h. The hydrolyzatefrom each vial was completely emptied into microcentrifuge tubes andeach vial was rinsed with 250 μL water and emptied into respectivemicrocentrifuge tube. The resulting solution was then evaporated undervacuum at room temperature. About 1 mL of 1.0 M sodium bicarbonatebuffer (pH 9.5) was weighed into each tube to neutralize the remainingacid. For individual amino acid analysis, a weighed amount of 3504 ofhydrolyzed protein solution and 350 μL of o-phthaldialdehyde reagentsolution were combined in a microcentrifuge tube, vortexed for 15 s, andimmediately injected onto a C18 column fitted with a guard column (totaltime from mixing to injection <1 min), using a previously reported HPLCmethod for AAA with o-phthaldialdehyde reagent (S3). Samples were eluted(gradient elution) with mobile phases of methanol:water (65:35) (A) andmethanol:THF:50 mM phosphoric acid (20:20:960) (titrated to pH 7.5 with10 N NaOH) (B) at a flow rate of 1.4 mL/min. Gradient elution conditionswere 40% A for 0.5 min, 17 min concave gradient to 50% A, 15 min lineargradient to 100% A, 5 min isocratic elution with 100% A, 7.5 min lineargradient to 40% A, and isocratic 40% A for 5 min. Amino acids weredetected by measuring fluorescence respectively at an excitation andemission wavelength of 350 and 455 nm. Protein and standards werequantified using the average of the 3 individual amino acids standardsfound to be stable under hydrolysis conditions: alanine, phenylalanine,and lysine.

Scanning electron microscopy (SEM): Surface morphology of microsphereswas examined by taking SEM images using a Hitachi 53200N scanningelectron microscope (Hitachi, Tokyo, Japan). Briefly, microspheres werefixed previously on a brass stub using double-sided adhesive tape andthen were made electrically conductive by coating, in a vacuum, with athin layer of gold (approximately 3 to 5 nm) for 60 s at 40 W. Thesurface view images of microspheres were taken at an excitation voltageof 5-10 kV.

Confocal microscopy: Distribution of self-microencapsulated protein inthe PLGA microspheres was observed by taking confocal images ofBSA-coumarin loaded PLGA microspheres. Briefly, 1 mg of BSA-coumarinloaded PLGA microspheres were suspended in 80 μL of water. A droplet ofthis suspension was placed on a clean glass slide, a glass cover slipplaced on top of the droplet, and excess of water was removed. Sampleswere imaged at an excitation/emission wavelength of 384/480 nm using aconfocal microscope (Olympus America Inc., Center Valley, Pa., USA).

Determination of polymer matrix porosity of SM microencapsulatingmicrospheres: Measurement of polymer matrix porosity of blank SMmicroencapsulating PLGA microspheres was done by Porous Materials, Inc.(Ithaca, N.Y., USA) using an AMP-60K-A-1 mercury porosimeter, generatingpore volume versus pressure data. The pore volume was reported as volumeper gram microspheres (cc/g). Total microsphere volume was calculated asthe sum of the pore volume and the polymer volume, where the polymerdensity (1.25 g/cc for 51 kDa PLGA 50:50, provided by manufacturer) andweight of the porosimetry sample were used to calculate the pore volume.Percent porosity was calculated as the pore volume per total microspherevolume. Pressure associated with microspheres' packing and surfacewetting, before mercury intrusion into the pores had taken place, wasnot calculated into the fmal pore volume as has been reported previously(S4). The method of determination of porosity utilized large amount ofmicrospheres sample (˜250 mg) and there was no significant difference(p>0.05) among the different measurements (three measurements) of thesame formulation. Hence, only one test was run for the measurement ofpolymer matrix porosity of various SM microspheres formulations.

Kinetics of self-healing microencapsulation: About 50 mg of SM PLGA50:50 (M_(w)=51 kDa) microspheres were placed into separate tubes of 65mg/mL dextran-FITC (10,000 M_(w)). Microspheres were incubated at 4° C.for 20 h, and then transferred to 42.5° C. for 72 h, with approximately10% of microspheres removed at preset time points while replacing thevolume post sampling with fresh dextran-FITC solutions. Samplemicrospheres were washed 10-fold with distilled water, withcentrifugation at 3200 rpm for 10 min to collect the microspheres aftereach wash. The dextran-FITC was extracted using acetone to dissolve thePLGA and concentrating the insoluble dextran-FITC using centrifugation(10,000 rpm at 10 min), and repeating 3-fold. Dextran-FITC was dissolvedin PBS, pH 7.4, and loading was determined via HPLC with fluorescence(without column seperation) using 20 or 40 μL injection volume and a 1mL/min PBS, pH 7.4 mobile phase. The fluorescence of the dextran-FITCwas measured respectively at an excitation and emission wavelength of490 and 520 nm.

Evaluation of testosterone suppression in rats following injection ofleuprolide acetate self-encapsulated PLGA micro spheres: The ability ofPLGA self-healing microencapsulation to provide long-term in vivorelease was evaluated by assessing long-term testosterone suppressionafter a single injection of leuprolide acetate self-encapsulated PLGAmicrospheres in male Sprague-Dawley rats (S5-S8). The treatment ofexperimental animals was in accordance with University committee on useand care of animals (University of Michigan UCUCA), and all NIHguidelines for the care and use of laboratory animals. MaleSprague-Dawley rats of 6 weeks old were housed in cages and given freeaccess to standard laboratory food and water, and allowed one week toacclimate prior to study initiation. Animals were anesthetized with 2-4%isoflurane administered by a calibrated vaporizer (Midmark, OrchardPark, N.Y., USA). The leuprolide acetate self-encapsulated PLGAmicrospheres (1×2-month dose), leuprolide acetate solution (1×1-monthdose), and blank SM PLGA microspheres without drug (1× dose) in a liquidvehicle (1% w/v carboxymethylcellulose and 2% w/v mannitol), andcommercial 1-month Lupron Depot (Abbott Laboratories, North Chicago,Ill., USA) (2× dosing at days 0 and 28) were subcutaneously injected atthe back (lower neck portion) of rats (6 animals/study group). Totaldose of leuprolide acetate was based on 100 μg/kg/day. Animal bodyweight considered for dosing leuprolide acetate was 425 g which isprojected body weight of male Sprague Dawley rat at midpoint (day 28) ofthe study (as per the weight (g)/age (weeks) curve given by CharlesRiver Laboratories). Blood samples were collected via jugular vein stickbefore (day −7 and 0 for baseline testosterone level) and after (1, 7,14, 21, 28, 35, 42, 49, and 56 days) injection of preparations. Thecollected blood samples were immediately transferred to B-D Microtainer™blood collection and serum separation tubes previously incubated in ice,centrifuged at 8,000 rpm for 10 min, and then the serum was removed andstored in microcentrifuge tubes at −20° C. until further use. Serumtestosterone levels were assayed by radioimmunoassay using aTESTOSTERONE Double Antibody-125I RIA Kit (MP Biomedicals LLC., Solon,Ohio, USA) at the University of Pennsylvania Diabetes Center(Philadelphia, Pa., USA). Lowest detection limit of testosterone was 0.1ng/mL. In case of samples which exhibited testosterone level below thedetection limit, a 0.1 ng/mL value was used for statistical evaluationand plotting the curve.

Sterilization of active SM (Al(OH)₃—PLGA) PLGA microspheres with gammairradiation: Active SM PLGA microspheres were irradiated by using ⁶⁰Coas irradiation source (Michigan Memorial Phoenix Project, University ofMichigan) at 2.5 MRad dose and 0.37 MRad/h dose rate. Briefly, about 250mg active SM PLGA microspheres were freeze-dried, placed in 5-mLampoules and then ampoules were sealed under vacuum. All the sampleswere irradiated at room temperature.

Statistical Analysis: The results are expressed as mean±standard errorof mean (n=3 or 5 or 6). An unpaired Student's t-test was used to assessstatistical significance between numerous SM PLGA microsphereformulations with respect to polymer porosity, protein and peptideloading, stability, and in vitro release, and in vivo testosteronelevel. Results were considered statistically significant if p<0.05.

Goodness of self-encapsulation—Effect of pore-forming excipients/initialwater phase volume on lysozyme loading and initial burst release: Thegoodness of self-encapsulation in PLGA microspheres as indicated byelevated lysozyme loading (open bar chart) and minimal initial burst(closed bar chart) of enzyme employing diversity of pore-formingexcipients/initial water phase volume to create the PLGA 50/50 porenetwork is shown in FIG. 4.

Limitations on molecular size—Self-microencapsulation of dextran blue:As suggested by the open pore distribution in FIG. 1 (before and afterloading lysozyme in SM microspheres) very large molecules can penetratethe polymer pore network and become encapsulated. Therefore, we testedthe virtual upper limit of molecular size of biomacromolecules byencapsulating TMR-dextran M_(w)=2 MDa) relative to low molecular weight4 kDa FITC-dextran in SM-PLGA 50:50 M_(w)=51 kDa) microspheres (SM-3,Tables 1 and 2). At a constant solution concentration of 1 mg/mL, whichis just below the solubility of the TMR-dextran, both dyes weresuccessfully encapsulated at very similar levels as indicated by thefollowing data determined experimentally (five measurements): SM PLGAmicrospheres self-encapsulated 0.30±0.01 and 0.22±0.01% w/w TMR-dextranand FITC-dextran 4 kDa, respectively.

Self-healing microencapsulation of leuprolide acetate in PLGA 50:50(M_(w)=51 kDa) microspheres (SM-5, Tables 1 and 2) is shown in FIG. 5.

Protection of protein during microencapsulation—Improved stability oflysozyme through self-microencapsulation: As lysozyme is a common modelprotein for testing protein damage during microencapsulation, weself-microencapsulated this enzyme and monitored its loading in terms ofmonomeric, total, and enzymatically active protein content. Thestability of lysozyme encapsulated via self-healing microencapsulation(SM-3 and SM-4, Tables 1 and 2) was compared with the enzymeencapsulated via a traditional w/o/w process (TM-1, Tables 1 and 2).Combined soluble and insoluble lysozyme encapsulated was measured viaAAA, and the soluble fractions were determined by SE-HPLC.

Addition of sucrose, as a differentially soluble material, either toinner water phase in the double emulsion (TE method) or loading solution(self-microencapsulation method) resulted in reduced lysozyme loading (%w/w lysozyme/polymer matrix). For example, the lysozyme loading intomedium M_(w) PLGA (M_(w)=51 kDa) microspheres prepared by TE with andwithout sucrose in WP was 0.65±0.01 and 4.86±0.04%, respectively (threemeasurements). Whereas lysozyme loading into medium M_(w) PLGA (M_(w)=51kDa) microspheres by the self-encapsulation technique with and withoutsucrose in loading solution was 3.39±0.03 and 5.17±0.08%, respectively(three measurements).

The percentage (% w/w) of loaded lysozyme that exists as intact solublemonomer was slightly higher for the self-microencapsulated microsphere(SM-3, Tables 1 and 2) formulations than the TM-1 formulations. In theabsence of sucrose, TM-1 and SM PLGA M_(w)=51 kDa) microspheres had 85±2and 90±2% intact monomer (three measurements), respectively. In thepresence of sucrose in the loading solution, SM PLGA (M_(w)=51 kDa)microspheres had 98±2% of the loaded protein as intact monomer (threemeasurements). Importantly, the fraction of total lysozyme loaded asinsoluble aggregates was significantly less (p<0.05) forself-microencapsulation technique when compared to TE method. Forexample, lysozyme loaded via TE method (TM-1, Tables 1 and 2) underwent40±4% and 12±2% insoluble aggregation (three measurements) with orwithout sucrose in the inner water phase, respectively (FIGS. 2F and E).By contrast, the self-microencapsulation technique respectively showed8±3 and 1±2% insoluble aggregation (three measurements) without and withsucrose in loading solution (FIGS. 2C and D) for the SM PLGA (M_(w)=51kDa) microsphere formulation (SM-3, Tables 1 and 2).

Protection of protein (BSA and lysozyme) against acid-induced proteininstability during release from self-encapsulated PLGA microspheres: Thesuccess of controlled protein delivery vehicles based on PLGAsignificantly depends upon the ability of the polymer to retain andrelease the stable form of proteins under physiological conditions overextended release times. Co-encapsulation of MgCO₃ along with proteins inPLGA 50:50 by the TE method has been used to stabilize proteins againstthe acidic polymer microclimate and released the proteins in a stableform compared to control formulations without an ionic affinity trap. AsBSA is a common model protein for assessing protein damage due to acidproduced by the PLGA polyester during long-term controlled release, weself-microencapsulated the protein into SM-PLGA 50:50 microspherescontaining MgCO₃ as an acid-neutralizer and porosigen with and withouttrehalose as an additional porosigen (SM-3, Tables 1 and 2) andmonitored its loading, release from microspheres and acid-inducedaggregated protein content in the polymer. Blank SM PLGA 50:50 (M_(w)=51kDa) microspheres containing 3 and 4.5% w/w (MgCO₃/polymer matrix) MgCO₃self-microencapsulated 4.25±0.05 and 5.65±0.06% w/w (protein/polymermatrix), respectively (three measurements). Both theself-microencapsulated formulations exhibited a high initial burst(49-54% BSA release after 1-day), which was then substantially reducedby co-encapsulation of trehalose along with MgCO₃ during the preparationof SM microspheres (FIG. 6A). Importantly, analysis of the remainingprotein in the microspheres after 28 days of in vitro release provided amass balance (total recovery) between 109±4 to 121±2% (threemeasurements) and out of which <2% BSA was aggregated.

Another model protein, lysozyme, was similarly self-encapsulated inblank PLGA 50:50 (M_(w)=51 kDa) microspheres (SM-3, Tables 1 and 2)containing 0, 1.5, 4.3, 11.0% w/w (MgCO₃/polymer matrix). The amount oflysozyme self-encapsulated in 0, 1.5, 4.3, 11.0% w/w MgCO₃ loaded blankPLGA 50:50 microspheres was 4.5±0.2, 6.4±0.1, 9.8±0.3, and 8.7±0.4% w/w(lysozyme/polymer matrix), respectively (three measurements). Therelease rate of lysozyme from above mentioned formulations was directlyrelated to the amount of ionic affinity trap (MgCO₃) loaded into theblank PLGA 50:50 microspheres (FIG. 6B). For example, after 28 days, thecumulative amount of lysozyme released from self-microencapsulatedmicrospheres formulations was 30±1, 41±1, 51±4, and 57±4% respectivelyfor 0, 1.5, 4.3, and 11.0% w/w MgCO₃ loaded blank PLGA 50:50microspheres. The amount of protein remaining in the microspheres after28 days of release, including soluble monomer, soluble aggregates, andinsoluble aggregates, was similarly quantified and >90% mass balance(total recovery) was achieved for all four formulations. For example,total amount of lysozyme recovered from self-microencapsulatedmicrospheres formulations was 92±2, 91±1, 99±4, and 110±4% (threemeasurements) respectively for 0, 1.5, 4.3, and 11.0% w/w MgCO₃ loadedPLGA 50:50 microspheres. Importantly, the total amount of solubleprotein, both released over 28 days and recovered as residual solublemonomer, was significantly higher (p<0.05) for 4.3 and 11.0% w/wMgCO₃-based self-encapsulated microspheres formulations. For example,total (released+residual) amount of soluble protein recovered for 0,1.5, 4.3, and 11.0% w/w MgCO₃ loaded PLGA 50:50 microspheres was 83±2,85.0±1, 95±4, and 107±4%, respectively. Furthermore, the specificactivity of the residual lysozyme remaining in the self-encapsulatedmicrospheres after 28 days of release was analyzed. The specificactivity was calculated based upon the total amount of soluble proteinanalyzed, both monomer and aggregated. The specific activity, given asthe percentage of the specific activity of the native, standard lysozymewas 102±6, 116±19, 100±5, and 97±5% respectively for 0, 1.5, 4.3, and11.0% w/w MgCO₃ loaded PLGA 50:50 microspheres. Thus, the solublelysozyme retained in the self-microencapsulated microspheres after 28days of release was still completely active within experimental errorfor all formulations.

Kinetics of PLGA self-encapsulation: In order to determine the timerequired for self-healing of PLGA to encapsulate large molecules, SMPLGA microspheres (SM-3, Table 1) were loaded with FITC-dextran (SM-3,Table 2) and the loaded biomacromolecular dye was analyzed at varioustimes before and after initiating self-encapsulation by increasingtemperature from 4° C. (T<T_(g)) to 42.5° C. (T>T_(g)). At each timepoint, microspheres were washed extensively with ddH₂O to remove anyunencapsulated dye. As shown in FIG. 1F, only background levels ofdextran were loaded when at the low temperature for 20 h. However, afterincreasing temperature to 42° C. (at time 0) loading of two separate,but equivalent, formulations both increased steadily over 12 h reachinga maximal and steady loading value for 72 h. Hence, without anymanipulation of the polymer (e.g. by plasticization) self-healing timefor this formulation was on the order of 12 h. In addition, loading wascompletely reproducible for the two identical formulations.

PLGA self-healing microencapsulation provides long-term delivery ofbioactive large molecules in vivo—Long-term testosterone suppression inrats after single injection of leuprolide acetate self-encapsulated PLGAmicro spheres: Leuprolide acetate (M_(w)=1209.6 Da) is commonly used inthe treatment of hormone-dependent cancers (e.g., prostate cancer) andgynecologic disorders (e.g., endometriosis and precocious puberty).Commercially available injectable PLGA microsphere-based formulation ofleuprolide (Lupron Depot™) is prepared by the traditional(water-in-oil-water) encapsulation method. The ability of PLGAself-healing microencapsulation to provide long-term in vivo release wasevaluated by assessing long-term testosterone suppression in maleSprague-Dawley rats (six rats/study group) in comparison with commercialLupron Depot™ and negative controls (FIG. 2C). The initial serumtestosterone level (1-2 ng/mL) increased to ˜5 ng/mL after one day ofsubcutaneous injection of Lupron Depot™′ leuprolide self-encapsulatedPLGA microspheres and leuprolide solution. This initial elevation istypical to treatment with luteinizing hormone-releasing hormone (LHRH)agonists (e.g., leuprolide acetate) resulting from initial stimulationof pituitary LHRH receptors and increased release of luteinizing hormone(LH), thereby stimulating testicular steroidogenesis and release ofgonadotropins. The testosterone levels fell below the castration level(0.5 ng/mL) within a week and remained under that level for 6-7 weeksfollowing a single injection of leuprolide acetate self-encapsulatedPLGA microspheres and 8 weeks after two injections (day 0 and 28) ofLupron Depot™. Importantly, there was no significant serum testosteronelevels difference (p<0.05) between self-encapsulated PLGA microspheresand commercial Lupron Depot™ over a period of 6 weeks, indicatingequivalent potential of new PLGA self-healing microencapsulationparadigm to provide long-term in vivo delivery of peptide drugs. Incontrast, leuprolide solution control because of the short serumhalf-life of the peptide, failed to provide testosterone suppressionbelow the castration level during the whole study duration. However,there was a significant serum testosterone levels difference (p>0.05)between negative controls (blank SM PLGA microspheres and leuprolidesolution) and long-term leuprolide delivery vehicles (self-encapsulatedPLGA microspheres and commercial Lupron Depot™) over a period of 6-8weeks.

Active self-microencapsulation of protein with high encapsulationefficiency by Al(OH)₃-PLGA microspheres—Effect of hydrophobicplasticizer: The encapsulation efficiency of SM PLGA microspheres by thepassive self-encapsulation method is 1.5-13%. In addition, aspartitioning of the proteins between polymer pores and externalsolutions should be close to unity when loading by the passive process,high external protein concentrations (e.g., >−100 mg/mL) were requiredpreviously to achieve loading >1%. Therefore, to increase theencapsulation of efficiency of SM PLGA micro spheres and to reduceexternal protein concentration, we added a known protein sorbing ionicaffinity trap, Al(OH)₃, in SM PLGA microspheres (ASM PLGA microspheres,Table 1) and tested their potential to self-microencapsulate differentvaccine antigens (ovalbumin (OVA) and tetanus toxoid (TT)), from lowaqueous protein concentrations (0.5 or 0.8 or 1.0 mg/mL) (Tables 2-5).

As shown in Table 3, all the three ASM (ASM-1, ASM-2, and ASM-3) PLGAmicrospheres sorbed the OVA from surrounding protein solution within theincubation time compared blank porous PLGA microspheres, suggestingactive self-microencapsulation of protein by ASM PLGA micro spheres.Negative loading values were observed with porous blank (no Al(OH)₃)microspheres which can be attributed to the uptake of small amounts ofwater by the polymer leaving behind more concentrated protein solution.

TABLE 3 OVA mass loss kinetics as a function of incubation time fromOVA/active SM Al(OH)₃-PLGA 50:50 (M,,, = 51 kDa) microspheres mixture.Formulation code Temp. and t IM^(a) Remaining OVA mass insolution^(a)(μg)* OVA loaded (μg)* ° C. h (μg) Blank ASM-1 ASM-2 ASM-3Blank ASM-1 ASM-2 ASM-3 10 3 404 415 ± 5 325 ± 3 317 ± 6 319 ± 3 −11 ± 579 ± 3 87 ± 6  85 ± 3 6 404 415 ± 3 321 ± 4 310 ± 4 310 ± 1 −11 ± 3 83 ±4 94 ± 4  94 ± 1 24 404 416 ± 2 315 ± 3  300 ± 10 301 ± 6 −12 ± 2 89 ± 3104 ± 10 103 ± 6 48 404 425 ± 3 285 ± 3 285 ± 7 284 ± 4 −21 ± 3 119 ± 3 119 ± 7  120 ± 4 25 + 37 24 + 30 404 419 ± 6 203 ± 4 212 ± 5 197 ± 3 −15± 6 201 ± 4  192 ± 5  208 ± 3 Temp and t: incubation temperature (° C.)and duration (h); IM: initial OVA mass in solution ^(a)volume = 0.4 mL;*Mean ± SE, n = 6 ASM-1: 3.2% w/w Al(OII)₃/3.5% w/w trehalose/0% w/wdiethyl phthalate (DEP)/PLGA microspheres ASM-2: 3.2% w/w Al(OH)₃/3.5%w/w trehalose/2.5% w/w DEP/PLGA microspheres ASM-3: 3.2% w/wAl(OH)₃/3.5% w/w trehalose/5% w/w DEP/PLGA microspheres

TABLE 4 OVA loading and self-microencapsulation efficiency of active SMAl(OH)₃-PLGA 50:50 (M_(w) = 51 kDa) microspheres at different initialloading concentration. Initial OVA Remaining OVA OVA recoveredEncapsulation OVA mass^(a) OVA mass^(a) loaded from polymerefficiency^(b) Loading^(b) FC (μg) (μg)* (μg)* (μg)* (%)* (% w/w)* ASM-1202.1  7.1 ± 2.4 195.0 ± 2.4 194.1 ± 2.2 96.1 ± 1.1 1.00 ± 0.01 404.1203.2 ± 4.3 200.9 ± 4.3 197.9 ± 3.1 49.0 ± 0.8 0.98 ± 0.02 ASM-2 202.1 4.4 ± 0.4 197.7 ± 0.4 196.2 ± 0.3 97.1 ± 0.2 0.97 ± 0.01 404.1 211.8 ±5.4 192.3 ± 5.4 190.5 ± 5.6 47.1 ± 1.4 0.90 ± 0.03 ASM-3 205.7  2.5 ±1.6 203.2 ± 1.6 202.1 ± 1.3 98.3 ± 1.1 1.00 ± 0.05 404.1 196.6 ± 2.7207.5 ± 2.7 203.5 ± 3.4 50.4 ± 1.7 1.00 ± 0.03 FC: formulation code;^(a)volume = 0.4 mL; *Mean ± SE, n = 6; ^(b)based on the OVA content inthe polymer ASM-1: 3.2% w/w Al(OH)₃/3.5% w/w trehalose/0% w/w diethylphthalate (DEP)/PLGA microspheres ASM-2: 3.2% w/w Al(OH)₃/3.5% w/wtrehalose/2.5% w/w DEP/PLGA microspheres ASM-3: 3.2% w/w Al(OH)₃/3.5%w/w trehalose/5% w/w % DEP/PLGA microspheres

With 400 μg initial incubation mass of OVA from 1 mg/mL OVA, the activeASM PLGA micro spheres self-microencapsulated about 200 μg(self-microencapsulation capacity=1% w/w (OVA/polymer matrix)) therebyexhibiting self-microencapsulation efficiency of about 50% (Table 4).

The similar loading of the three preparations (ASM-1, ASM-2, and ASM-3)also indicated that the protein loading was governed by the effectivecapacity of the Al(OH)₃ for sorbing OVA when the external OVA contentexceeded the Al(OH)₃ sorbing capacity available in the polymer.Therefore, the encapsulation efficiency was further increased bydecreasing external OVA content to roughly that encapsulated (˜200 μg)previously, that is, by incubating microspheres with 200 μg OVA from 0.5mg/mL OVA. As expected, ASM-1, ASM-2, and ASM-3 microspheresself-microencapsulated almost the entire OVA mass, thereby exhibitingextraordinary self-microencapsulation efficiency (96-98%) (Table 4). Thepotential of active SM PLGA microspheres to activelyself-microencapsulate very sensitive vaccine antigen (TT) aftersterilization of blank microspheres with gamma radiations wasinvestigated and compared with the results obtained prior to irradiation(Table 5). There was no significant difference in active loading of TTbefore and after sterilization of active SM PLGA micro spheres,indicating the effectiveness of this novel strategy to self-encapsulatevaccine antigens after terminal sterilization of microspheres. Forexample, with 400 μg initial incubation mass of TT from 0.8 mg/mLloading solution, all the active SM PLGA microsphere formulationsself-encapsulated TT equivalent to about 1.6% w/w polymer loading and87% encapsulation efficiency (3 measurements).

TABLE 5 Effect of gamma irradiation of active self-microencapsulatingPLGA microspheres on active loading and encapsulation efficiency oftetanus toxoid (TT). Initial TT Remaining Encapsulation mass^(a) TTmass^(a) TT loaded TT Loading^(b) efficiency^(b) (μg)* (μg)* (μg)* (%w/w)* (%)* Unencapsulated 400 0.0 400.0 ± 0.0 Al(OH)₃ ^(c) Beforeirradiation ASM-1 400 53.7 ± 1.9 346.3 ± 1.9 1.62 ± 0.02 86.6 ± 0.5ASM-2 400 52.2 ± 1.4 347.8 ± 1.4 1.66 ± 0.03 86.9 ± 0.4 Afterirradiation^(s) ASM-1 400 52.8 ± 1.2 347.2 ± 1.2 1.64 ± 0.03 86.8 ± 0.3ASM-2 400 53.2 ± 0.6 346.8 ± 0.6 1.61 ± 0.03 86.7 ± 0.2 ^(a)volume = 0.5mL; *Mean ± SE, n = 3; ^(b)based on the TT mass loss from solution;^(c)mass of Al(OH)₃ = 0.6 mg ASM-1: 3.2% w/w Al(OH)₃/3.5% w/wtrehalose/0% w/w diethyl phthalate (DEP)/PLGA microspheres ASM-2: 3.2%w/w Al(OH)₃/3.5% w/w trehalose/5% w/w DEP/PLGA microspheres;^(d)irradiation dose and dose rate were 2.5 MRad at 0.37 MRad/h.

The effect of encapsulation of Al(OH)₃ and blending of hydrophobicplasticizer (diethyl phthalate (DEP)) on the self-healing phenomenon ofPLGA 50:50 (M_(w)=51 kDa) microspheres is shown in FIG. 7.

It is noted that the Al(OH)₃ gel appeared to suppress self-healing aspores still appeared after incubation of the active SM PLGA microspheresat 43° C. (FIG. 7) as compared to full healed microspheres preparedwithout Al(OH)₃ gel (FIG. 7). Hence, we sought to increase PLGA mobilityby incorporating a hydrophobic plasticizer in the polymer. For example,diethyl phthalate (DEP) was blended with the polymer while preparingblank Al(OH)₃—PLGA microspheres. As expected, with increasing amount ofhydrophobic plasticizer in PLGA, pore-closing (self-healing) at 37° C.was clearly visible in FIG. 7, indicating that any suppression ofself-healing by Al(OH)₃ could be overcome by the hydrophobicplasticizer.

It can be emphasized that SM PLGA microspheres with respectively 3.2,3.5, and 5% w/w of Al(OH)₃, trehalose and DEP were found to be anoptimal formulation for active self-healing microencapsulation ofprotein at physiological temperature (37° C.) with high encapsulationefficiency. Moreover, the successful employment of DEP to reduce therequired temperature for self-healing opens-up the door toself-microencapsulate temperature-sensitive molecules in higher M_(w)PLGA at or below physiological temperature.

Evaluation of quality of active protein self-microencapsulation inAl(OH)₃—PLGA microspheres: Evaluation of quality of active proteinself-encapsulation in Al(OH)₃—PLGA (M_(w)=51 kDa) (ASM PLGA)microspheres was tested first in 190 mM sodium citrate solution, abuffer commonly used to elute protein antigens completely from Al(OH)₃adjuvant within 3 days. The release of OVA from active self-encapsulatedAl(OH)₃—PLGA microspheres was significantly different (p<0.05) comparedto unencapsulated Al(OH)₃ (FIG. 8). For example, ASM-3 PLGA microspheres(3.2% w/w Al(OH)₃/3.5% w/w trehalose/5% w/w DEP/PLGA microspheres)largely retained OVA (i.e., 60-73%) after 1-day of exposure to thecitrate buffer, whereas unencapsulated Al(OH)₃ released all the protein(97±0.8% release). In addition, ASM-3 PLGA microspheres released OVAslowly in a controlled manner over a period of 10 days (48±4.4% release(three measurements) after 10 days), indicating an effective activeself-encapsulation of protein in Al(OH)₃—PLGA microspheres. After 10days of release duration, the remaining OVA (soluble and insoluble) inASM-3 PLGA microspheres was recovered as described in the OVA recoverymethod. After 10 days of release, 47±6.4% soluble monomer and 5.8±0.8%insoluble aggregate (covalent and non-covalent) was recovered from ASM-3PLGA microspheres with a total recovery of 100.8±0.8% (threemeasurements).

Long-term controlled release of proteins from ASM PLGA (Al(OH)₃—PLGA)micro spheres: The potential of PLGA active self-encapsulation toprovide long-term release of stable proteins was evaluated by assessingOVA monomer and antigenic TT release from unencapsulated Al(OH)₃ andactive self-encapsulated without (ASM-1) and with (ASM-3) 5% w/wDEP—Al(OH)₃—PLGA microspheres (Tables 3-5) in PBS (pH 7.4) (FIG. 3C) orPBS+0.02% Tween™ 80+0.2% BSA (FIG. 3D) at 37° C. The release of OVAmonomer or antigenic TT from ASM-3 PLGA microspheres (3.2% w/wAl(OH)₃/3.5% w/w trehalose/5% w/w DEP/PLGA microspheres) was alsosignificantly different (p<0.05) than unencapsulated Al(OH)₃ (FIGS. 3Cand D). For example, OVA-Al(OH)₃ control gel exhibited 76, 90, and 99%OVA monomer release and TT-Al(OH)₃ control gel exhibited 87, 95, and 98%antigenic TT release respectively after 1, 3, and 7 days. In contrast,ASM-3 PLGA microspheres exhibited very less initial burst (17% OVAmonomer or 32% antigenic TT release after 1 day) and provided slow andcontinuous release of OVA monomer or antigenic TT over a period of 28days (49 and 68% OVA monomer or 83 and 99% antigenic TT releaserespectively after 14 and 28 days). After 28 days of release, 19±3%soluble OVA monomer and 10±2% insoluble OVA aggregate (covalent andnon-covalent) was recovered from ASM-3 PLGA microspheres with a totalrecovery of 98±3% (three measurements).

As the microencapsulation of vaccine antigens in Al(OH)₃—PLGAmicrospheres can be easily performed by simple of mixing of vaccineantigens/Al(OH)₃—PLGA microspheres and heating the mixture tophysiological temperature (no harsh manufacturing conditions), this newapproach opens-up a new mode for sustained vaccine delivery similar to ainjectable peptide formulation (e.g., Lupron depot), thereby improvingthe stability and efficacy of vaccine antigens. Note that injectablePLGA microspheres represent an approach to control the release ofvaccine antigens to reduce the number of doses in the immunizationschedule and optimize the desired immune response via selectivetargeting of antigen to antigen presenting cells.

Accordingly, the present technology provides delivery systems havinghigh encapsulation efficiencies for one or more various agents. Thedelivery system can include an ionic affinity trap, such as a metalsalt, in combination with a solid polymer matrix to enable a largeportion or substantially the entire amount of an agent outside thepolymer to enter pores in the polymer, for example, where the agent issubsequently encapsulated following self-healing of the polymer.

The delivery system includes a solid polymer matrix. The solid polymermatrix can include a polymer, such as a self-healing polymer, and caninclude one or more pores, an ionic affinity trap, an agent, andanything else associated with the delivery system. For example, thesolid polymer matrix can include a self-healing polymer that includesone or more pores including an ionic affinity trap that can be used tosorb an agent, where the pores are then partially or completely closedto encapsulate the agent and prevent it from leaving the pore(s). Thepolymer can include a porous self-healing polymer that is able to alterits shape following a treatment. For example, open pores within theself-healing polymer can partially or completely close following atemperature change to sequester contents of the pores. Encapsulationefficiencies greater than 99% can be achieved. A further advantage isthat the solution concentration of the agent to be encapsulated can beless than the concentration used in passive methods; e.g., about 1 mg/mLof agent in the present methods versus roughly 100 mg/mL or greateramounts of agent in passive methods. This opens the door to encapsulatean agent having a low aqueous solubility and/or an agent that is onlyavailable in limited quantities. Likewise, the amount of residual agentleft in the solution following encapsulation can be significantlydecreased, thereby making the present methods more proficient andeconomical. In some embodiments, the delivery system comprises aself-healing polymer, where a portion of the self-healing polymercomprises ionized end groups and an agent sorbed to the ionized endgroups.

Various embodiments of the present technology can include the followingaspects. The self-healing polymer can be biodegradable and can degradeor erode over time. The ionic affinity trap may also act as an adjuvantin some cases. The delivery system can further include the use of aplasticizer to plasticize the polymeric material and manipulate thetemperature at which self-healing begins to occur. Control of theseproperties can be important for encapsulation of certain agents that maybe damaged at elevated temperatures (e.g., 43° C. or higher) commonlyused with moderate molecular weight self-healing polymers.

In some embodiments, the delivery system can include a porousself-healing polymer, optionally a differentially soluble material suchas a saccharide or disaccharide, and one or more ionic affinity trapsand plasticizers. The differentially soluble material can be employed toobtain a porous self-healing polymer network and/or to stabilize thepolymeric material. The ionic affinity trap and plasticizer can improvethe encapsulation efficiency and the self-healing property of thepolymer, respectively. A self-healing polymer having a porous network,such as PLGA microspheres, can be prepared using established methods,such as those described in U.S. Pat. Appl. Pub. 2008/0131478 toSchwendeman et al.; Sophocleous et al., J. of Controlled Release 137(2009) 179-184; Kang et al., Molecular Pharmaceutics, vol. 4, no. 1,104-118 (2007); Cui et al., Vaccine 25 (2007) 500-509; and Jiang et al.,Advanced Drug Delivery Reviews 57 (2005) 391-410.

In accordance with the present methods, a solution comprising an agentis placed in contact with a self-healing polymer having pores or onethat can form pores when in contact with the solution. At the same timeor following a soaking period, the self-healing polymer experiences acondition that causes spontaneous polymer chain rearrangement, which inturn causes the accessible pores (pores having access to the polymersurface) to close. The agent becomes entrapped, encapsulated, orabsorbed within the self-healing polymer when these pores close.

In some embodiments, the self-healing polymer can be:poly(dicyclopentadiene); poly(dimethyl siloxane); poly(diethoxysiloxane); furan-maleimide-based polymers; dicyclopentadiene-basedpolymers; anthracene-maleimide based polymers;1,1,1-tris-(cinnamoyloxymethyl) ethane (TCE)-based polymers; poly(ethylene-co-butylene); methyl methacrylate (MMA) embeddedpolypropylene fibers; epoxy with a urea-formaldehyde microcapsule;ionomers including hydrocarbon polymers bearing pendant carboxylic acidgroups that are either partially or completely neutralized with metal orquaternary ammonium ions (e.g., Surlyn 8920, Surlyn 8940, Nucrel 960,and Nucrel 925); epoxy resins-diglycidyl ether of bisphenol A,diglycidyl ether of bisphenol F; and combinations thereof. Also includedare self-healing polymeric materials having reactive furfurylfunctionality, including poly(furfuryl methacrylate) and poly(furfurylmethacrylate)-co-poly(methyl methacrylate), as described by Kavitha etal., Applied Materials & Interfaces, vol. 1, no. 7, 1427-1436 (2009).Also included are self-healing polymeric materials based onfuran-functionalized, alternating thermosetting poly ketones andbis-maleimide, as described by Zhang et al., Macromolecules 2009, 42,1906-1912. The polymeric material can also be a biodegradable material.And the polymeric material can be in several forms, including particlessuch as particles, including microspheres, and various shapes of tissueengineering scaffolds.

In some embodiments, the self-healing polymer can be copolymers oflactic acid and glycolic acid (PLGA) and related copolymers, includingany polymer containing a polyester with lactic and/or glycolic acidrepeat units. The polymers may be made using any method, and may belinear, star, branched, cross-linked, or any configuration so long asthe polymer has lactic and/or glycolic repeat units, which may beliberated by hydrolysis. In accordance with the methods describedherein, the pore-containing polymers may be preformed prior to theencapsulation step; i.e., the microparticles, microspheres, tissueengineering scaffold, nanoparticles, drug-eluting stent, suture, orscrew may be formed according to known methods prior to contact with theagent to be encapsulated.

PLGA is a polyester composed of one or more of three different hydroxyacid monomers, d-lactic, I-lactic, and/or glycolic acids. In general,the polymer, can be made to be highly crystalline (e.g., poly(l-lacticacid)), or completely amorphous (e.g., poly(d,l-lactic-co-glycolicacid)), can be processed into most any shape and size (e.g., down to<200 nm), and can encapsulate molecules of virtually any size. PLGAmicrospheres and other injectable implants have an established safetyrecord and are used in several different marketed products from variouscompanies worldwide. For example, these controlled-release products arecapable of controlling the release of peptides and proteins slowly andcontinuously from about 1 to 6 months, or even longer.

In addition to the depot effect, smaller PLGA microparticles (e.g., lessthan 10 μm) have demonstrated adjuvant activity via their uptake bymacrophages and dendritic cells (DCs), and their localization in lymphnodes, and to induce cytotoxic T lymphocyte (CTL) responses. Forexample, despite the biocompatibility of PLGA, the mild inflammatoryresponse produced by PLGA microspheres is hypothesized as being involvedin their adjuvant characteristics. Most significant are reports oflong-lasting antibody responses, many neutralizing above protectivelevels, in numerous animal models following a single dose of PLGAmicroparticle encapsulated antigens including displays of immunologicalmemory after 1 year of immunization and protection against challenge.

PLGA can be in the form of particles, such as microspheres, which can beprepared using a double emulsion-solvent evaporation microencapsulationmethod. For example, PLGA along with a saccharide or disaccharide, suchas trehalose, and CH₂Cl₂ can be homogenized at 10,000 rpm using aTempest IQ2 homogenizer (The VirTis Company, Gardiner, N.Y.) equippedwith a 10 mm shaft in an ice/water bath for 1 min to prepare the firstemulsion. Two milliliters of 5% (w/v) PVA solution can then beimmediately added to the first emulsion and the mixture vortexed (Genie2, Fisher Scientific Industries, Inc., Bohemia, N.Y.) for 15 sec. toproduce the w/o/w double emulsion. The resulting emulsion can be pouredinto 100 mL of 0.5% (w/v) PVA solution under rapid stirring and hardenedat room temperature for about 3 hours. Hardened microspheres can becollected by centrifugation, washed three times with purified water, andfreeze-dried. For freeze-drying, samples can be flash-frozen in liquidnitrogen and placed on a Freezone 6 freeze-drying system (Labcono,Kansas City, Mo.) at 133×10⁻³ mbar or less vacuum at a condensertemperature of −46° C. for 48 hours. Three percent MgCO₃ powder (w/w ofpolymer) can suspended in the polymer solution before encapsulation whenionic affinity trap-containing PLGA microspheres are desired.

Morphology and size distribution of the microspheres can by ascertainedby scanning electron microscopy. For example, microspheres can be firstcoated with gold for 200 sec. by a vacuum coater (Desk II, DentonVacuum, Inc., Hill, N.J.). Microsphere morphology can then be observedusing a scanning electron microscope (S3200N Variable Pressure SEM,Hitachi) with a voltage of 15 keV. For size distribution analysis, thesize of more than 200 particles can be measured from SEM micrographs andthe weight-averaged mean radius of the microspheres can be calculated.To observe the microsphere cross section, polymer specimens can bepre-cut by a razor blade on a glass slide before coating with gold.

In some embodiments, the delivery system can be prepared as follows.PLGA microparticles loaded with an ionic affinity trap (e.g.,Alhydrogel) can be prepared by a water/oil/water (w/o/w) emulsionmethod. Briefly, alhydrogel can be concentrated to the desiredconcentration by removing water. Trehalose solutions (double therequired concentration) can be prepared by dissolving the requiredamount in 50 mM succinate buffer. Alhydrogel and trehalose can then bemixed at 1:1 (v/v) ratio. Polymer solution (1 mL) can be prepared bydissolving the required amount of PLGA (250 or 350 mg/mL) in methylenechloride. About 200 or 300 μL of initial water phase can be added toPLGA solution followed by homogenization at 17,000 rpm for 60 seconds.Then, 2 mL of 5% PVA (9-10 k, 80% hydrolyzed) can be immediately addedto the mixture and vortexed for 50 seconds. The resulting emulsion canthen be poured into 100 mL of 0.5% PVA (9-10 k, 80% hydrolyzed) undercontinuous stirring. The resulting microspheres can be stirred for about3 hours at room temperature, collected and washed thoroughly by passingthrough sieves of different mesh size. Microspheres can then beflash-frozen with liquid nitrogen and immediately freeze-dried.

Before encapsulation of an agent, the self-healing material comprisingthe self-healing polymer can be acceptably terminally sterilized (e.g.,by gamma irradiation) with little or no loss in polymer molecularweight. A sterile solution of agent and sterile microspheres ofpolymeric material can then be combined to effect encapsulation. In somecases, a sterile agent solution can be added to sterile and drymicrospheres.

During microsphere formation, the polymer can be subjected to numerousstresses (e.g., excess heat, mixing, etc.) that normally cannot be usedafter loading the agent because certain agents (e.g.,peptide/protein/DNA) may degrade under such conditions. In addition, theelement of control over the ultimate polymeric material morphology andthe kind of microsphere prepared can be vastly increased ifencapsulation is performed after microsphere (scaffold) preparation.

In some embodiments, the self-healing polymer can be in variousconfigurations, and is not limited to particles or microspheres, forexample. The self-healing polymer can be formed in various shapes andarticles of various sizes. For example, the self-healing polymer can beused as a polymer coating on drug-eluting stents, prepared asnanopartices, and formed into tissue engineering scaffolds, includingshapes that replace portions of tissue or shapes that conform to varioustissues. For example, the materials and methods provided herein are alsoapplicable to self-healing materials used as tissue engineeringscaffolds, as well as any type of biomaterial or any other polymerencapsulation system (e.g., agricultural) that requires the need toencapsulate molecules that do not strongly partition into the polymerphase, but instead are encapsulated within the pores of a self-healingpolymer. This is particularly useful for aqueous-based materials such asbiological materials present in their native state in aqueous solution.

To load the microspheres, the microspheres can be incubated in anaqueous solution comprising an agent, where the agent can be at a fairlylow concentration (e.g., about 0.5 to 1 mg/mL). The aqueous mixture ofpolymeric material and agent can then be incubated between about 10° C.to about 43° C. over a period of time, for example, ranging from hoursto days. During this incubation, the porous network of the polymericmaterial heals thereby encapsulating the agent with a high encapsulationefficiency (e.g., >99%). Incubation temperature for loading the agentinto the delivery system varies as the composition of the polymericmaterial varies; e.g., with or without an plasticizer. The incubatingtemperature can be tuned from about 10° C. to about 43° C. to achieve avery high encapsulation efficiency of the agent and to improve theself-healing property of the polymer. With the use of plasticizer, forexample, self-healing of a moderate molecular weight polymer can occurreadily at about 37° C. instead of about 43° C.

Thus, the self-healing polymer can be combined with a solutioncomprising an agent at a relatively low concentration, where nearly theentire amount of agent is taken up into the polymer pores, and the agentis then encapsulated within the polymer following self-healing of thepolymer, where each step includes applying an appropriate temperatureadjustment.

In some embodiments, the encapsulation efficiency (weight of agentencapsulated/weight agent in solution exposed to polymer) is greaterthan 50%. In some embodiments, the encapsulation efficiency is greaterthan 60%. In some embodiments, the encapsulation efficiency is greaterthan 70%. In some embodiments, the encapsulation efficiency is greaterthan 80%. In some embodiments, the encapsulation efficiency is greaterthan 90%. In some embodiments, the encapsulation efficiency is greaterthan 95%. And in some embodiments, the encapsulation efficiency isgreater than 99%.

A differentially soluble material, such as a saccharide or similarmaterial, can be used in forming the pores in the self-healing polymericmaterial. For example, after forming microparticles from a mixture ofsaccharide and polymer, the saccharide portion can be dissolved withoutdissolving the polymer to leave empty pores in the polymer. Usefulsaccharides include disaccharides such as trehalose, sucrose, andlactose. Other saccharides that can be used include polysaccharides,such as dextran, and glycosaminoglycans, such as heparin. The saccharidecan be used to stabilize an ionomer gel used as the ionic affinity trap,for example, as described by A L Clausi, S A Merkley, J F Carpenter, T WRandolph, J Pharm Sci 97, 2049 (2008). Other pore-forming saccharidesthat can be used include mannose and mannitol.

In some embodiments, the differentially soluble material can include awater-soluble osmotic material in order to create the pores in a porousself-healing polymer. For example, Mg and Al salts can be used to createa percolating pore network; i.e., pores that interconnect with thesurface of the polymer. Other basic salts are described by Zhu et al. inPharmaceutical Research, Vol. 17, No. 3, 2000. For example, usefulcomponents for making pores and/or stabilizing proteins include thosedescribed in S. E. Bondos, A. Bicknell, Analytical Biochemistry 316(2003) 223-231. Examples of such materials that may promote proteinsolubility include: kosmotropes including MgSO₄ at 0-0.4 M, NH₄SO₄ at0-0.3 M, Na₂SO₄ at 0-0.2 M, Cs₂SO₄ at 0-0.2 M; weak kosmotropesincluding NaCl 0-1 M, KCl 0-1 M; Chaotropes including CaCl₂ 0-0.2 M,MgCl₂ 0-0.2 M, LiCI 0-0.8 M, RbCI 0-0.8 M, NaSCN 0-0.2 M, NaI 0-0.4 M,NaClO₄ 0-0.4 M, NaBr 0-0.4 M, Urea 0-1.5 M; Amino acids includingglycine 0.5-2%, L-arginine 0-5 M; sugars and polyhydric alcoholsincluding Sucrose 0-1 M, Glucose 0-2 M, Lactose 0.1-0.5 M, Ethyleneglycol 0-60% v/v, Xylitol 0-30% w/v, Mannitol 0-15% w/v, Inositol 0-10%w/v, Sorbitol 0-40% w/v, Glycerol 5-40% v/v; Detergents including Tween80 0-0.2% w/v, Tween 20 0-1201M, and Nonidet P-40 0-1%; and combinationsthereof.

Ionic affinity traps used to sorb an agent in the present deliverysystems include bases such as metal salts and metal hydroxides. Theionic affinity trap may also be in the form of a gel and can includevarious ionomers. For example, aluminum hydroxide and calcium phosphategels are known as ionomers. Of the various metal salts and hydroxides,aluminum hydroxide and aluminum phosphate are two such ionic affinitytraps that are particularly useful. Some ionic affinity traps mayfurther act as an adjuvant to stimulate the immune system and increasethe response to a vaccine. For example, where the agent is amacromolecule such as a protein antigen, the ionic affinity trap mayalso perform as an adjuvant when the delivery system is used forvaccination.

In some embodiments, the ionic affinity trap can include aluminumhydroxide and/or aluminum phosphate. Commercial forms of aluminumhydroxide (Alhydrogel™, 2%) and aluminum phosphate (Adju-Phos™) areavailable from Accurate Chemical and Scientific Corporation (Westbury,N.Y.). These aluminum materials can also act as adjuvants when thepresent delivery system is used with or as a vaccine. Aluminum hydroxideand aluminum phosphate can be prepared by exposing aqueous solutions ofaluminum ions to alkaline conditions under very controlledcircumstances, which in the case of aluminum phosphate takes place inthe presence of phosphate ions. Various soluble aluminum salts can beused for the production of the ionic affinity trap, but the experimentalconditions—temperature, concentration and even rate of addition ofreagents—can strongly influence the results. Other metal salts that canbe used as an ionic affinity trap include those disclosed in Zhu et al.in Pharmaceutical Research, Vol. 17, No. 3, 2000.

Colloidal or sub-colloidal suspensions of aluminum hydroxide can becharacterized by particle size distribution, electrical charge, and thehydrated colloid nature of the precipitate formed. Alterations of thepreparation recipe can give rise to various forms of aluminum hydroxidewhich differ with respect to their physico-chemical characteristics,stability and protein adsorption.

Several models for the structure of aluminum hydroxide exist. One modeltakes form in a ring-structure of six members, each member consisting ofan Al³⁺ surrounded by six coordinated water molecules in an octohedralshape. The coordinated water molecules are oriented with the oxygentoward the aluminum ion. The high charge of the Al³⁺ is believed toweaken the bond between oxygen and hydrogen thus facilitating theremoval of protons, especially under alkaline conditions.Deprotonization, thus facilitated by the alkalinity, is believed to leadto the initial formation of dimers by dihydroxyl bridges betweenoctohedras and later to the formation of the six-membered ring-structureand even larger structures. In this process, the ratio of aluminium tohydroxide approaches 1:3. On the basis of this model the chemicalformula Al(OH)₃ is misleadingly simple. The model thus described is ageneralized model that does not consider crystalline forms or inclusionof other ions. When inclusion of other ions, originating from the saltsused in the preparation, is taken into consideration aluminium hydroxideprecipitated from aluminium chloride can be described asAl(OH)_(2.55)(Cl)_(0.45), existing as a polymer of ten fusedsix-membered rings and if precipitated from sulphate asAl(OH)_(2.30)(SO4)_(0.35) and based on three fused such rings.

When X-ray crystallography and IR spectroscopy are applied to aluminiumgel preparations, a boehmite-like (aluminium oxyhydroxide) pattern isseen in preparations known as aluminium hydroxide, whereascommercialized aluminium phosphate gel adjuvant is identified asamorphous aluminium hydroxyphosphate. It is possible to calculate anaverage primary crystallite size of 4.5 nm×2.2 nm×10 nm for boehmitepreparations.

The ionic affinity trap can bind agents such as proteins, includingprotein antigens, where the ionic affinity trap can be an aluminum saltadjuvant. Without the use of such adjuvants, proteins may be only weaklyimmunogenic. Aluminum salts are currently the only adjuvants generallyapproved for use in vaccines for humans. Despite their approved use, themechanism of action is still poorly understood. Among a variety ofnonmutually exclusive proposed mechanisms, roles as depots for antigeninduction of inflammatory responses and delivery of antigen into antigenpresenting cells are proposed.

The two most common aluminum salts employed as adjuvants are thephosphate and hydroxide forms. The salts themselves have been wellcharacterized with aluminum hydroxide (Alhydrogel™) can usually be foundin a crystalline state, whereas aluminum phosphate can exist in anamorphous form. The points of zero charge (analogous to the isoelectricpoint of a macromolecule) are 4.0-5.5 and about 11 for the phosphate andhydroxide salts, respectively. In general, proteins seem to betteradsorb to the oppositely charged salts through simple electrostaticeffects, although apolar and ion displacement interactions may play arole as well.

What happens to the structure and stability of proteins when they areadsorbed onto the surface of these two commonly employed aluminum saltsis not well characterized. When proteins are adsorbed to solid surfaces,highly polar (including charged) interfaces tend to minimally perturbprotein structure and stability, although exceptions are known. Incontrast, more apolar surfaces often significantly alter the structureand stability of many proteins. The effect of the aluminum salt onprotein structure and stability is important from several perspectives.For example, to the extent that epitopes are conformational in nature,their retention (or alteration) may be critical for vaccineimmunogenicity. The stability of protein antigens is equally importantwhen they are stored for long periods prior to their use. The latterstrongly impacts the utility of vaccines for use in the developingworld, where shipping under cold conditions can be problematic, and inthe use of vaccines against potential bioterrorism agents, where storagefor long periods in centralized locations may be critical for theireffectiveness.

In some embodiments, the ionic affinity trap can be calcium phosphate.Calcium phosphate can function as an adjuvant and can be used topotentiate the immune response of vaccines and to prepare adsorbedallergen extracts. It can be well tolerated and readily resorbed by thebody and it is believed to potentiate the immune response by the depotmechanism whereby the antigen is adsorbed during the preparation of thevaccine and slowly released following administration. Calcium phosphateis also believed to act by presenting the adsorbed antigen to antigenpresenting cells as a particulate antigen.

Calcium phosphate has a molecular composition close to Ca₃(PO₄)₂, wherethe calcium/phosphorus molar ratio (Ca/P) can vary from 1.35 to 1.83depending on the rate of mixing during the precipitation reaction. Theproperties of the precipitate are strongly dependent on theprecipitation conditions. For example, calcium phosphate precipitated byrapid mixing can adsorb about 100% of diphtheria toxoid while calciumphosphate precipitated by slow mixing can adsorb about 58% of the samedose of diphtheria toxoid.

Preparations of calcium phosphate are available from Reheis Inc.(Berkeley Heights, N.J.) and Brenntag Biosector (Frederikssund,Denmark).

Although its name suggests that it is Ca₃(PO₄)₂, X-ray diffraction, FTIRspectroscopy, thermal analysis, and the Ca/P molar ratio identifycommercial calcium phosphate as non-stoichiometric hydroxyapatite,Ca_(10-x)(HPO₄)_(x) (PO₄)_(6-x)(OH)_(2-x), where x varies from 0 to 2.The surface charge is also pH-dependent (point of zero charge=5.5).Consequently, commercial calcium phosphate exhibits a negative surfacecharge at physiological pH and electrostatically adsorbs positivelycharged materials, such as positively charged antigens. The presence ofhydroxyls can further allow calcium phosphate to adsorb phosphorylatedantigens by ligand exchange with surface hydroxyls.

Another useful ionic affinity trap is aluminum phosphate. And in someembodiments, the ionic affinity trap can be alum, which includesaluminum and potassium.

Other examples of ionic affinity traps include extracellular matrix-likematerials, including dextran sulfate, chitosan, and hyaluronic acid.

In some embodiments, there are a number of different ways to activelyload the polymer. (1) Layer-by-layer assembly based on charge. Forexample, start with a negatively charged agent, such as heparin, insidethe polymer pores and then bind heparin-binding growth factors; e.g.,fibroblast growth factors and vascular endothelial growth factors.Alternating incubations of growth factor and heparin create a network ofgrowth factor stabilized in between heparin layers; i.e., heparin-growthfactor-heparin-growth factor and so on. (2) Creating a gradient of asubstance from inside the polymer to outside that causes the protein toprecipitate in the polymer; e.g., with ammonium sulfate inside thepolymer. (3) Placing a nucleating agent for crystallization inside thepolymer at a concentration above saturation; e.g., using features asdescribed in U.S. Pat. No. 5,869,604. This includes using exogenousnucleating agents such as minerals, transition metal ions such as copperand lead, highly absorbent structures such as zeolites, preformedcrystal seeds of amino acids, and preformed crystal seeds ofpolypeptides other than the agent being loaded into the pores. (4)Creating a Donnan equilibrium (e.g., charged species that can not escapethe pores), forming a pH gradient, precipitating the protein at itsisoelectric pH. (5) Addition of a counterion to the pores of the polymerthat causes the protein to come out of solution as a stabilizedinsoluble salt; e.g., Zn²⁺ insulin or Zn²⁺ growth hormone using Znacetate in the polymer. (6) Placing a porous polymer with evacuatedpores in contact with a solution comprising the agent and releasingpressure so that the solution fills the pores.

A plasticizer can be used to plasticize the polymeric material andmanipulate the temperature at which self-healing begins to occur. Usefulplasticizers include diethyl phthalate, tributyl acetylcitrate, andsimilar compounds. Other useful plasticizers include those that (1)cause a pore network to form (e.g., by osmotic pressure), (2) stabilizethe encapsulated molecule, and (3) cause the encapsulated molecule topreferentially distribute inside the polymer pores (e.g., either insolution, in solid state, or sorbed to a structure of some kind)relative to the outside solution.

The agent to be encapsulated may be any material, compound, orbiomolecule of interest that can associate with the ionic affinity trap.The methods provided herein are particularly useful for agents thatwould be subject to degradation when exposed to conditions used inpreparing pore-containing polymers. Examples of agents includebiomolecules such as proteins, peptides, proteoglycans, lipoproteins,and nucleic acids, such as RNA and DNA. Some non-limiting examples ofproteins that may be used with the present methods include bovine serumalbumen, hen egg-white lysosome, ribonuclease A, growth hormone, tetanustoxoid, erythropoietin, insulin-like growth factor-I, vascularendothelial growth factor, bone morphogenetic protein, and basicfibroblast growth factor.

In some embodiments, the agent can be a small molecule or a largecolloidal particle (e.g., virus), or any bioactive substance, such as abiomacromolecule. The only caveat is that the agent to be encapsulatedshould have an affinity for the ionic affinity trap. In this way, theagent can be present at a low concentration (e.g., 1 mg/mL or lower) sothat the ionic affinity trap acts to bind and effectively load theporous polymeric material with the agent. Loading of the porouspolymeric material is therefore not dependent on passive diffusion,which typically requires a high concentration of agent to be loaded inorder to obtain the desired loading level.

The present technology may also be used for small molecules, e.g., drugsused in drug-eluting stents or in nanoparticle delivery. Hydrophilicmolecules can be problematic to encapsulate in drug-eluting stents byconventional methods. The present technology may also be used toencapsulate nanoparticulate materials (e.g., viruses) without drying thepolymer. For example, some materials may be denatured or degraded inwhole or part by a drying process and hence the present methods canavoid drying is such instances.

To further illustrate the present technology, another example of PLGAmicrospheres loaded with ovalbumin can be prepared as follows todemonstrate an embodiment of a delivery system constructed in accordancewith the present technology. The effects of formulation and incubationparameters on agent loading were ascertained indicated in Tables 6-13.Ovalbumin is used as a model to demonstrate loading of a proteinantigen, for example. The following parameter effects were determined.

TABLE 6 Effect of alhydrogel loading (theoretical). IncubationTemperature Ovalbumin Adsorbed (μg)* and Time Alhydrogel Loading(Theoretical) (wt %) T (° C.) t (h) Blank 0.7 1.3 3.2 25 3 −0.7 ± 3.842.4 ± 2.4 70.9 ± 7.9 87.6 ± 2.8 6 −4.0 ± 2.7 62.5 ± 4.9 73.0 ± 1.0 91.2± 1.7 24 −7.1 ± 9.3 65.3 ± 9.9 77.8 ± 6.3 95.4 ± 1.9 *Mean ± S.EConcentration of PLGA: 350 mg/mL; Initial water phase: 200 μL, Trehaloseloading: 7.8 wt %; Microparticles size: 20-63 μm

TABLE 7 Effect of trehalose loading (theoretical). IncubationTemperature Ovalbumin Adsorbed (μg)* and Time Trehalose Loading(Theoretical) (wt %) T (° C.) t (h) 0 1.9 3.8 10.4 25 3 73.0 ± 7.1 75.1± 1.4 85.0 ± 2.8 84.2 ± 3.1 6 73.4 ± 5.3 82.7 ± 8.2 99.2 ± 3.3 85.5 ±3.3 24 80.0 ± 2.8 104.2 ± 1.8  111.0 ± 5.5  88.0 ± 7.9 *Mean ± S.E

Concentration of PLGA: 250 mg/mL; Initial water phase: 2004,

Alhydrogel loading: 2.9 to 3.2 wt %; Microparticles size: 20-63 μm

TABLE 8 Effect of volume of initial water phase. Incubation TemperatureOvalbumin Adsorbed (μg)* and Time Volume of Initial Water Phase (μL) T(° C.) t (h) 200 300 25 3 70.9 ± 7.9 50.7 ± 0.4 6 73.0 ± 1.0 68.1 ± 4.724 77.8 ± 6.3 73.2 ± 4.6 *Mean ± S.E Concentration of PLGA: 350 mg/mL;Alhydrogel loading: 1.35 and 1.93 wt %; Trehalose loading: 7.8 wt %;Microparticles size: 20-63 μm

TABLE 9 Effect of size of microparticles. Incubation TemperatureOvalbumin Adsorbed (μg)* and Time Size of Microparticles (μm) T (° C.) T(h) 20-63 63-90 25 3 75.4 ± 12.9 29.1 ± 9.0 6 79.5 ± 10.7 47.0 ± 9.7 2492.3 ± 5.5  59.2 ± 4.3 *Mean ± S.E Concentration of PLGA: 350 mg/mL;Alhydrogel loading: 1.35 wt % Trehalose loading: 14.4 wt %; Initialwater phase: 200 μL

TABLE 10 Effect of concentration of PLGA. Incubation TemperatureOvalbumin Adsorbed (μg)* and Time Concentration of PLGA (mg/mL) T (° C.)t (h) 250 350 25 3 84.2 ± 3.1 78.0 ± 5.8 6 85.5 ± 3.3 84.1 ± 2.3 24 88.0± 7.9 87.8 ± 4.1 *Mean ± S.E Alhydrogel loading: 2.9 wt %; Trehaloseloading: 14.4 wt % Initial water phase: 200 μL; Microparticles size:20-63 μm

TABLE 11 Effect of incubation temperature. Incubation TemperatureOvalbumin Adsorbed (μg)* and Time Incubation Temperature (° C.) T (° C.)t (h) 10 25 25 3 78.9 ± 2.6 85.0 ± 2.8 6 83.3 ± 3.4 99.2 ± 3.3 24 89.8 ±2.5 111.0 ± 5.5  *Mean ± S.E Concentration of PLGA: 250 mg/mL;Alhydrogel loading: 3.2 wt %; Trehalose loading: 3.8 wt %; Initial waterphase: 200 μL; Microparticles size: 20-63 μm

TABLE 12 Effect of adjuvant type. Incubation Ovalbumin Adsorbed (μg)*Temperature Adjuvant Type and Time Aluminum Calcium T (° C.) t (h)Hydroxide Phosphate 25 3 78.9 ± 2.6 55.7 ± 5.4 6 83.3 ± 3.4 58.7 ± 5.024 89.8 ± 2.5 82.0 ± 9.7 *Mean ± S.E Concentration of PLGA: 250 mg/mL;Alhydrogel loading: 3.2 wt %; Calcium Phosphate loading: 3.4 wt %;Trehalose loading: 3.8 wt %; Initial water phase: 200 μL; Microparticlessize: 20-63 μm

TABLE 13 Recovery of ovalbumin after release study in 194 mM Sodiumcitrate. Ovalbumin Ovalbumin Insoluble Released Recovered from aggregateTotal after 10 polymer after (covalent and Recovery Formulation days (%)10 days (%) noncovalent) (%) (%) 3.2 wt % Alhydrogel/PLGA 78.3 ± 4.621.0 ± 4.2 1.3 ± 0.2 100.6 ± 0.2 3.1 wt % Alhydrogel/5 47.9 ± 4.4 47.1 ±6.4 5.8 ± 0.8 100.8 ± 0.8 wt % DEP/PLA

Self-healing of microparticles loaded with ovalbumin is furtherillustrated in FIGS. 9-11. FIG. 9 depicts 3.2 wt % Alhydrogel/3.8 wt %Trehalose/PLGA microparticles before (A) and after (B) self-healing byincubating at about 25° C. for about 24 hours and about 43° C. for about48 hours. FIG. 10 depicts 3.2 wt % Alhydrogel/3.8 wt % Trehalose/2.5 wt% DEP/PLGA microparticles before (A) and after (B) self-healing byincubating at about 10° C. for about 48 hours, at about 25° C. for about24 hours, and at about 37° C. for about 30 hours. FIG. 11 depicts 3.2 wt% Alhydrogel/3.8 wt % Trehalose/5 wt % DEP/PLGA microparticles before(A) and after (B) self-healing.

In another example of the present technology, a delivery system is usedto microencapsulate Leuprolide, a potent agonistic analogue ofluteinizing hormone-releasing hormone, inhibits the secretion ofpituitary gonadotropin when administered chronically in therapeuticdoses. Microsphere depot formulations of leuprolide can be developed forlong-term testosterone suppression.

In some embodiments, the present technology can employ “sorptionloading.” Basically, this involves taking ground PLGA of relatively lowMW (from the manufacturer), which has ionized end group (in this casecarboxylate, but could be made anything), and then incubating lowpeptide solution concentrations. The ionic interaction causes thepeptide to “sorb” to the polymer. The full nature of this sorption isnot fully understood, other than it requires the ionized end group and ahigh enough temperature for polymer chain mobility. It could be mostlyat the surface, i.e., adsorption, or mostly in the bulk, i.e.,absorption. The sorption group in FIG. 13 is generated with injectionsevery two, three, or four weeks at the same dosage as the Lupron Depot.The polymer is of low MW and takes up more water than the polymersgenerated for most self-healing microencapsulation methods. In thisexample, we expect the peptide sorbs by penetration directly into thepolymer phase and combines with carboxylic end groups (the ionicaffinity trap), as the acid end-group PLGA takes up sufficient water forpeptide permeation.

Evaluation of long-term testosterone suppression ability of leuprolideacetate (LA)-PLGA particles in male Sprague-Dawley rats was performed asfollows.

The efficacy of LA-PLGA particles to provide long-term in vivo LArelease was evaluated by assessing long-term testosterone suppressionability of LA-PLGA particles in male Sprague-Dawley rats. The treatmentof experimental animals was in accordance with University committee onuse and care of animals (University of Michigan UCUCA), and all NIHguidelines for the care and use of laboratory animals. MaleSprague-Dawley rats of 6 weeks old were housed in cages and given freeaccess to standard laboratory food and water, and allowed one week toacclimate prior to study initiation. Animals were anesthetized with 2-4%isoflurane administered by a calibrated vaporizer (Midmark, OrchardPark, N.Y., USA). The leuprolide acetate (1×) and LA-PLGA particles(2×(day 0, 14, 28, and 42), 3×(day 0, 21, and 42), and 4×(day 0 and 28)in a liquid vehicle (1% w/v carboxymethylcellulose and 2% w/v mannitol),and commercial Lupron Depot (2×(day 0 and 28)) were subcutaneouslyinjected at the back (lower neck portion) of rats (6 animals/studygroup). The dose of leuprolide acetate was 100 μg/kg/day. Animal bodyweight considered for dosing leuprolide acetate was 425 g which isprojected body weight of male Sprague Dawley rat at midpoint (day 28) ofthe study (as per the weight (g)/age (weeks) curve given by CharlesRiver Laboratories). Blood samples were collected via jugular vein stickbefore (day −7 and 0 for baseline testosterone level) and after (1, 7,14, 21, 28, 35, 42, 49, and 56 days) injection of preparations. Thecollected blood samples were immediately transferred to B-D Microtainer™blood collection and serum separation tubes previously incubated in ice,centrifuged at 8,000 rpm for 10 min, and then the serum was removed andstored in microcentrifuge tubes at −20° C. until further use. Serumtestosterone levels were assayed by Radioimmunoassay using aTESTOSTERONE Double Antibody-1251 RIA Kit (MP Biomedicals LLC., Solon,Ohio, USA) at the University of Pennsylvania Diabetes Center(Philadelphia, Pa., USA). Lowest detection limit of testosterone was 0.1ng/mL.

The following methods were employed. Aspects of leuprolide acetate (LA)sorption by PLGA particles include the following. Previously grinded andsieved (20-63 μm) PLGA was used for the absorption of LA to PLGA.Solution (3 mM) of LA in HEPES (0.1 M, pH 7.4) was added to PLGAparticles (1 mL/10 mg particles) and incubated on a rotary shaker at 37°C. After 6 h of incubation, LA equivalent to 1 mM was added to boost theconcentration gradient and hence LA absorption to PLGA. After 24 hincubation, LA/PLGA particles mixture was centrifuged at 8000 rpm for 10min and supernatant was removed. The residual particles were washedthree times with deionized water (1 mL water/10 mg particles) and thenfreeze-dried. LA absorbed PLGA particles were passed through sieves toobtain 20-63 μm and stored at −20° C. until further use.

Aspects of determining leuprolide acetate loading in leuprolideacetate-PLGA particles include the following. LA content in LA-PLGAparticles was determined by two-phase extraction. Briefly, about 10 mgLA absorbed PLGA 50:50 (Resomer° RG 502H) particles (n=3) were weighedinto 5 mL glass vials. To these vials, 1 mL of methylene chloride and 2mL of 50 mM sodium acetate (pH 4.0) were added, followed by vortexingfor 1 min. One and half milliliter of buffer layer was removed, replacedwith 1.5 mL of same buffer (5 extractions) or 50 mM sodium acetate+1 MNaCl (6 extractions) and similarly extracted for 11 times. The contentof LA in each extracted fraction was then analyzed and quantified byHPLC. Eleven extractions found to be sufficient to remove LA completelyfrom LA-PLGA complexes as the peak of LA disappeared in 12^(th)extraction.

Evaluation of in vitro release of leuprolide acetate from LA-PLGAparticles was as follows. In vitro release of LA was performed underperfect sink condition. Briefly, about 10 mg LA-PLGA particles wereweighed (n=3) into Eppendorf tubes and 1 mL of PBST+0.02% sodium azidewas added. Eppendorf tubes were then incubated at 37° C. on a rotaryshaker at 240 rpm. At specified time points (1-10 days and every twodays thereafter), tubes were centrifuged at 8,000 rpm for 5 min and 1 mLsupernatant was removed and then replaced with pre-warmed (37° C.)release medium. Analysis of LA in release samples was performed by HPLC.

The following results were obtained.

TABLE 14 Evaluation of leuprolide acetate (LA) content in LA-PLGAparticles. LA loading (wt %) Amino acid LA loading Extraction analysisefficiency LA absorbed Fraction of method method (%) (μmol/g PLGA) acidsoccupied' 17.2 ± 2.2 17.0 ± 2.7 33.2 ± 0.1 140.8 ± 10.9 0.68 ± 0.05 ^(a)Fraction of acids occupied = LA absorbed/total acids of polymer (μmol/gPLGA).

In vitro release of leuprolide acetate from LA-PLGA particles is shownin FIG. 12.

In vivo testosterone suppression in male Sprague-Dawley rats byleuprolide acetate in PLGA particles is shown in FIG. 13.

Benefits of the current technology include: a) the ability to prepareagent encapsulated products in a straightforward manner, b) reduction inthe cost of manufacturing as loss of expensive agents duringencapsulation is reduced and a smaller quantity of agent (about 0.5 to 1mg/mL) can be used to achieve very high encapsulation efficiency (99% ormore), c) can be used with multiple agents, d) can be used atpoint-of-care, and e) allows terminal sterilization of the deliverysystem prior to agent loading (i.e., no aseptic manufacturing withorganic solvents is required).

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms, and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail. Equivalent changes, modifications and variations ofsome embodiments, materials, compositions and methods can be made withinthe scope of the present technology, with substantially similar results.The following non-limiting discussion of terminology is provided withrespect to the present technology.

The headings (such as “Introduction” and “Summary”) and sub-headingsused herein are intended only for general organization of topics withinthe present disclosure, and are not intended to limit the disclosure ofthe technology or any aspect thereof. In particular, subject matterdisclosed in the “Introduction” may include novel technology and may notconstitute a recitation of prior art. Subject matter disclosed in the“Summary” is not an exhaustive or complete disclosure of the entirescope of the technology or any embodiments thereof. Classification ordiscussion of a material within a section of this specification ashaving a particular utility is made for convenience, and no inferenceshould be drawn that the material must necessarily or solely function inaccordance with its classification herein when it is used in any givencomposition.

The description and specific examples, while indicating embodiments ofthe technology, are intended for purposes of illustration only and arenot intended to limit the scope of the technology. Moreover, recitationof multiple embodiments having stated features is not intended toexclude other embodiments having additional features, or otherembodiments incorporating different combinations of the stated features.Specific examples are provided for illustrative purposes of how to makeand use the compositions and methods of this technology and, unlessexplicitly stated otherwise, are not intended to be a representationthat given embodiments of this technology have, or have not, been madeor tested.

As used herein, the words “desire” or “desirable” refer to embodimentsof the technology that afford certain benefits, under certaincircumstances. However, other embodiments may also be desirable, underthe same or other circumstances. Furthermore, the recitation of one ormore desired embodiments does not imply that other embodiments are notuseful, and is not intended to exclude other embodiments from the scopeof the technology.

As used herein, the word “include,” and its variants, is intended to benon-limiting, such that recitation of items in a list is not to theexclusion of other like items that may also be useful in the materials,compositions, devices, and methods of this technology. Similarly, theterms “can” and “may” and their variants are intended to benon-limiting, such that recitation that an embodiment can or maycomprise certain elements or features does not exclude other embodimentsof the present technology that do not contain those elements orfeatures.

Although the open-ended term “comprising,” as a synonym ofnonrestrictive terms such as including, containing, or having, is usedherein to describe and claim embodiments of the present technology,embodiments may alternatively be described using more limiting termssuch as “consisting of or “consisting essentially of.” Thus, for anygiven embodiment reciting materials, components or process steps, thepresent technology also specifically includes embodiments consisting of,or consisting essentially of, such materials, components or processesexcluding additional materials, components or processes (for consistingof) and excluding additional materials, components or processesaffecting the significant properties of the embodiment (for consistingessentially of), even though such additional materials, components orprocesses are not explicitly recited in this application. For example,recitation of a composition or process reciting elements A, B and Cspecifically envisions embodiments consisting of, and consistingessentially of, A, B and C, excluding an element D that may be recitedin the art, even though element D is not explicitly described as beingexcluded herein. As referred to herein, all compositional percentagesare by weight of the total composition, unless otherwise specified.Disclosures of ranges are, unless specified otherwise, inclusive ofendpoints and include all distinct values and further divided rangeswithin the entire range. Thus, for example, a range of “from A to B” or“from about A to about B” is inclusive of A and of B. Disclosure ofvalues and ranges of values for specific parameters (such astemperatures, molecular weights, weight percentages, etc.) are notexclusive of other values and ranges of values useful herein. It isenvisioned that two or more specific exemplified values for a givenparameter may define endpoints for a range of values that may be claimedfor the parameter. For example, if Parameter X is exemplified herein tohave value A and also exemplified to have value Z, it is envisioned thatParameter X may have a range of values from about A to about Z.Similarly, it is envisioned that disclosure of two or more ranges ofvalues for a parameter (whether such ranges are nested, overlapping ordistinct) subsume all possible combination of ranges for the value thatmight be claimed using endpoints of the disclosed ranges. For example,if Parameter X is exemplified herein to have values in the range of1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may haveother ranges of values including 1-9,1-8,1-3,1-2,2-10,2-8, 2-3,3-10, and3-9.

“A” and “an” as used herein indicate “at least one” of the item ispresent; a plurality of such items may be present, when possible.“About” when applied to values indicates that the calculation or themeasurement allows some slight imprecision in the value (with someapproach to exactness in the value; approximately or reasonably close tothe value; nearly). If, for some reason, the imprecision provided by“about” is not otherwise understood in the art with this ordinarymeaning, then “about” as used herein indicates at least variations thatmay arise from ordinary methods of measuring or using such parameters.

When an element or layer is referred to as being “on,” “engaged to,”“connected to” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to” or “directly coupled to” another element orlayer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

1. A method of making a solid delivery system comprising: providing abiodegradable polymer matrix having no peptide disposed within thematrix structure; and admixing the biodegradable polymer matrix with anaqueous solution of an peptide under conditions sufficient to sorb thepeptide to the biodegradable polymer matrix, thereby forming asuspension of particles or microspheres of a biodegradable polymermatrix having the peptide disposed within the matrix structure, whereinthe temperature of the aqueous solution and formed suspension is at orabove the hydrated Tg of the polymer; wherein the biodegradable polymermatrix comprises a copolymer of lactic acid and glycolic acid havingionized carboxylate end groups, and the polymer matrix partially orfully encapsulates the peptide thereby forming the solid deliverysystem.
 2. The method of claim 1, wherein the peptide comprises apositively charged biomolecule, drug, or antigen.
 3. The method of claim2, wherein the peptide comprises a moderate molecular weight peptide. 4.The method of claim 3, wherein the peptide absorbs to the biodegradablepolymer matrix.
 5. The method of claim 1, wherein the biodegradablelactic acid and glycolic acid polymer matrix comprises a microparticleor a porous microsphere.
 6. The method of claim 1, wherein the admixingcomprises incubating the aqueous solution of the peptide with thebiodegradable polymer within 24 hours.
 7. (canceled)
 8. The method ofclaim 1, wherein the solid delivery system provides sustained release ofthe peptide over at least two weeks.
 9. The method of claim 1, whereinthe peptide is encapsulated at greater than 30% encapsulationefficiency.
 10. The method of claim 1, wherein the particles of thebiodegradable polymer matrix comprises a microparticle or a porousmicrosphere.
 11. The method of claim 10, wherein the microspheres have adiameter in a range of about 20 to about 63 micron.
 12. The method ofclaim 1, further comprising sterilizing the biodegradable polymer matrixprior to admixing with the aqueous solution of the peptide. 13.(canceled)
 14. The method of claim 1, wherein the admixing step is freeof organic solvents.
 15. The method of claim 1, wherein thebiodegradable polymer matrix comprises poly(D,L-lactic-co-glycolic acid)50:50.
 16. The method of claim 1, further comprising isolating the soliddelivery system from the aqueous solution.
 17. A method of making asolid delivery system comprising: providing solid, dried, particles of abiodegradable polymer matrix having an interconnected porous structureand an ionic affinity trap operable to sorb an agent from an aqueoussolution disposed within the pores of the porous structure, and no agentdisposed within the porous structure; and admixing the biodegradablepolymer matrix with an aqueous solution of an agent under conditionssufficient to bind the agent to the ionic affinity trap, thereby forminga suspension of particles or microspheres of a biodegradable polymermatrix having the agent disposed within the porous structure, whereinthe temperature of the aqueous solution and formed suspension is at orbelow the hydrated Tg of the polymer; wherein the polymer matrixpartially or fully encapsulates the agent, thereby forming the soliddelivery system, and wherein the aqueous solution comprises less than100 mg/mL of the agent and the agent is encapsulated at greater than 50%encapsulation efficiency. 18.-50. (canceled)
 51. A solid delivery systemcomprising: particles of a biodegradable polymer matrix having aninterconnected porous structure, an ionic affinity trap disposed withinthe pores of the porous structure, and an agent disposed within theporous structure; the ionic affinity trap and interconnected pores beingpresent in an amount sufficient to allow loading of at least 1% w/wagent into the pores, wherein the polymer matrix partially or fullyencapsulates the agent; wherein the ionic affinity trap comprisesaluminum hydroxide, aluminum phosphate, calcium phosphate, potassiumphosphate, or combinations thereof.
 52. A solid delivery systemcomprising: particles of a biodegradable polymer matrix having anpeptide disposed within the matrix structure; wherein the biodegradablepolymer matrix comprises a copolymer of lactic acid and glycolic acidhaving ionized carboxylate end groups, the peptide is bound to theionized carboxylate end groups of the copolymer and occupies about 68%or greater of the total acids of the copolymer, and the polymer matrixpartially or fully encapsulates the peptide.
 53. The solid deliverysystem of claim 1, wherein the peptide is selected from the groupconsisting of leuprolide acetate, octreotide acetate, and goserelinacetate.
 54. The solid delivery system of claim 1, wherein the peptideis leuprolide acetate.